Sealant-containing tire and related processes

ABSTRACT

Processes for producing a sealant layer-tire inner liner combination as well as a sealant layer-containing tire and related processes involving the sealant layer-containing tire are disclosed. The sealant layer is adhered to the tire inner liner, has a thickness of 2-8 mm and comprises 100 parts of at least one rubber, 90-500 phr of at least one tackifier, optionally one or more extenders, optionally at least one hydroscopic substance, and a cure package.

FIELD

The present application is directed to producing a sealant layer-innerliner combination, to a sealant layer-containing tire and to relatedprocesses involving the sealant layer-containing tire.

BACKGROUND

Sealants may be used in pneumatic tires to improve the operatingdurability (e.g., during driving) of a tire installed upon a vehicle.Use of a sealant may enable the pneumatic tire to withstand a puncture(e.g., from a sharp object such as a nail) which would otherwise causeundesirable loss of air from the tire. By incorporating a sealant intoan interior portion of a pneumatic tire, one or more punctures whichcould otherwise cause loss of air from the tire and/or render thevehicle inoperable can be plugged by movement of the sealant into thehole created by the puncture.

SUMMARY

Disclosed herein are processes for producing a sealant layer-inner linercombination. Also disclosed herein is a sealant layer-containing tireand related processes involving the sealant layer-containing tire.

In a first embodiment, a process for producing a sealant layer-innerliner combination is provided. The process comprises: (a) providing atire inner liner, wherein the inner liner includes a radially inwardfacing surface and a radially outward surface; (b) providing a sealantlayer having an upper surface, a lower surface, and a thickness of 2-8mm, and comprising a mixture of (i) 100 parts of at least one rubberselected from the group consisting of butyl rubber (optionallyhalogenated), natural rubber, polyisoprene, polybutadiene rubber,styrene-butadiene rubber, styrene-butadiene-isoprene rubber,isoprene-butadiene rubber, polychloroprene rubber, EPDM, nitrile rubber,polyisobutylene and combinations thereof; (ii) 90-500 phr of at leastone tackifier; (iii) optionally one or more extenders in a total amountof no more than 55 phr; (iv) optionally at least one hydroscopicsubstance in an amount of 0.5 to 10 phr; and (v) a cure package; and (c)adhering the sealant layer either to the radially inward facing surfaceof the inner liner so that the lower surface of the sealant layer facesradially outward, thereby producing a tire containing sealant or to theradially outward facing surface of the inner liner so that the lowersurface of the sealant layer faces radially outward.

In a second embodiment, a tire containing a sealant layer is provided.The tire comprises: one or more belts, a road-contacting tread, an innerliner with a radially inward facing surface and a radially outwardfacing surface, and a sealant layer having an upper surface, a lowersurface, and a thickness of 2-8 mm. According to the second embodiment,the sealant layer is adhered to either the radially inward facingsurface of the inner liner so that the lower surface of the sealantlayer faces radially outward or to the radially outward facing surfaceof the inner liner so that the lower surface of the sealant layer facesradially outward, and the sealant layer comprises a mixture of (i) 100parts of at least one rubber selected from the group consisting of butylrubber (optionally halogenated), natural rubber, polyisoprene,polybutadiene rubber, styrene-butadiene rubber,styrene-butadiene-isoprene rubber, isoprene-butadiene rubber,polychloroprene rubber, EPDM, nitrile rubber, polyisobutylene andcombinations thereof; (ii) 90-500 phr of at least one tackifier; (iii)optionally one or more extenders in a total amount of no more than 55phr; (iv) optionally at least one hydroscopic substance in an amount of0.5 to 10 phr; and (v) a cure package.

In a third embodiment, a process of recovering one or more components ofa used tire is provided. The process comprises providing a tirecontaining a sealant layer according to the second embodiment andremoving the sealant layer from the tire by separating the sealant layeraway from the inner liner.

In a fourth embodiment, a process for repairing a punctured tire isprovided. The process comprises providing a tire containing a sealantlayer according to the second embodiment wherein the tire contains atleast one puncture of the inner liner extending into a portion of thesealant layer. The process comprises identifying the at least onepuncture; repairing the at least one puncture either by (a) removing theportion of the sealant layer surrounding the puncture thereby creating agap in the sealant layer, and adhering a new portion of sealant to thegap; or (b) adding a new portion of sealant to the puncture; therebyrepairing the punctured tire.

DETAILED DESCRIPTION

Disclosed herein are processes for producing a sealant layer-inner linercombination. Also disclosed herein is a sealant layer-containing tireand related processes involving the sealant layer-containing tire.

In a first embodiment, a process for producing a sealant layer-innerliner combination is provided. The process comprises: (a) providing atire inner liner, wherein the inner liner includes a radially inwardfacing surface and a radially outward surface; (b) providing a sealantlayer having an upper surface, a lower surface, and a thickness of 2-8mm, and comprising a mixture of (i) 100 parts of at least one rubberselected from the group consisting of butyl rubber (optionallyhalogenated), natural rubber, polyisoprene, polybutadiene rubber,styrene-butadiene rubber, styrene-butadiene-isoprene rubber,isoprene-butadiene rubber, polychloroprene rubber, EPDM, nitrile rubber,polyisobutylene and combinations thereof; (ii) 90-500 phr of at leastone tackifier; (iii) optionally one or more extenders in a total amountof no more than 55 phr; (iv) optionally at least one hydroscopicsubstance in an amount of 0.5 to 10 phr; and (v) a cure package; and (c)adhering the sealant layer either to the radially inward facing surfaceof the inner liner so that the lower surface of the sealant layer facesradially outward, thereby producing a tire containing sealant or to theradially outward facing surface of the inner liner so that the lowersurface of the sealant layer faces radially outward.

In a second embodiment, a tire containing a sealant layer is provided.The tire comprises: one or more belts, a road-contacting tread, an innerliner with a radially inward facing surface and a radially outwardfacing surface, and a sealant layer having an upper surface, a lowersurface, and a thickness of 2-8 mm. According to the second embodiment,the sealant layer is adhered to either the radially inward facingsurface of the inner liner so that the lower surface of the sealantlayer faces radially outward or to the radially outward facing surfaceof the inner liner so that the lower surface of the sealant layer facesradially outward, and the sealant layer comprises a mixture of (i) 100parts of at least one rubber selected from the group consisting of butylrubber (optionally halogenated), natural rubber, polyisoprene,polybutadiene rubber, styrene-butadiene rubber,styrene-butadiene-isoprene rubber, isoprene-butadiene rubber,polychloroprene rubber, EPDM, nitrile rubber, polyisobutylene andcombinations thereof; (ii) 90-500 phr of at least one tackifier; (iii)optionally one or more extenders in a total amount of no more than 55phr; (iv) optionally at least one hydroscopic substance in an amount of0.5 to 10 phr; and (v) a cure package.

In a third embodiment, a process of recovering one or more components ofa used tire is provided. The process comprises providing a tirecontaining a sealant layer according to the second embodiment andremoving the sealant layer from the tire by separating the sealant layeraway from the inner liner.

In a fourth embodiment, a process for repairing a punctured tire isprovided. The process comprises providing a tire containing a sealantlayer according to the second embodiment wherein the tire contains atleast one puncture of the inner liner extending into a portion of thesealant layer. The process comprises identifying the at least onepuncture; repairing the at least one puncture either by (a) removing theportion of the sealant layer surrounding the puncture thereby creating agap in the sealant layer, and adhering a new portion of sealant to thegap; or (b) adding a new portion of sealant to the puncture; therebyrepairing the punctured tire.

-   Definitions

The terminology as set forth herein is for description of theembodiments only and should not be construed as limiting the inventionas a whole.

As used herein, the term “majority” means more than 50% (e.g., 50.5%,51%, 60%, etc.) and may encompass 100%.

As used herein, the term “natural rubber” or NR means naturallyoccurring rubber such as can be harvested from sources such as Hevearubber trees, and non-Hevea source (e.g., guayule shrubs, and dandelions(e.g., TKS)). In other words, the term “natural rubber” should not beconstrued as including polyisoprene.

As used herein, the term “phr” means parts per one hundred parts rubber.100 parts of rubber may also be referred to as 100 phr. As anon-limiting example, when an exemplary sealant composition comprises amixture of 60 parts of butyl rubber, 40 parts of EPDM rubber, and 100parts of polybutene tackifier, the amount of polybutene tackifier can bedescribed as 100 phr.

As used herein, the term “polyisoprene” means synthetic polyisoprene. Inother words, the term is used to indicate a polymer that is manufacturedfrom isoprene monomers, and should not be construed as includingnaturally occurring natural rubber (e.g., Hevea natural rubber,guayule-sourced natural rubber or dandelion-sourced natural rubber). Theterm polyisoprene is also used interchangeably with the phrase“polyisoprene rubber” and the abbreviation “IR.”

As used herein, the term “radially inward” is a relative term indicatingthat a component is positioned or arranged closer to or facing the innerportion of a tire, with the understanding that the road-contacting treadis generally the radially outermost portion of a tire. As a non-limitingexample, body plies within a tire are positioned radially inward of theroad-contacting tread of the tire.

As used herein, the term “radially outward” is a relative termindicating that a component is positioned or arranged closer to orfacing the outer portion of a tire, with the understanding that theroad-contacting tread is generally the radially outermost portion of atire. As a non-limiting example, the road-contacting tread of a tire ispositioned radially outward of the body plies within a tire.

As used herein, the phrases “inner liner” and “tire inner liner” areused interchangeably.

-   Sealant Layer

As discussed above, according to the first embodiment, the sealant layerthat is adhered to the tire inner liner has an upper surface and a lowersurface. The upper surface is the surface that is intended to faceradially inward when the sealant layer is assembled into a tire and thelower surface is the surface that is intended to face radially outwardwhen the sealant layer is assembled into a tire. As also discussedabove, according to the first-fourth embodiments, the sealant layer hasa radially inward facing surface and a radially outward facing surfacewherein either the radially outward facing surface (the lower surface)of the sealant layer is adhered to the radially inward facing surface ofthe inner liner or the radially inward facing surface of the sealantlayer (the lower surface) is adhered to the radially outward facingsurface of the inner liner. When the radially inward facing surface ofthe sealant layer is adhered to the radially outward facing surface ofthe inner liner, the opposite surface of the sealant layer (i.e., theupper surface or the radially outward facing surface) faces theremainder of the tire (e.g., the sealant layer is between the innerliner and the remainder of the tire). According to the first-fourthembodiments, the thickness of the sealant layer is 2 to 8 mm (e.g., 2,2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, or 8 mm). In certainembodiments of the first-fourth embodiments, the thickness of thesealant layer is 3-6 mm, 3-5 mm, 3-4 mm, or 4-5 mm. The thicknessesreferred to herein can be measured from the upper surface (which becomesradially inward facing) of the sealant layer) to the lower surface(which becomes radially outward facing) of the sealant layer such as bythe use of calipers. The foregoing thicknesses are also intended toencompass the overall thickness of the sealant layer for thoseembodiments of the first-fourth embodiments wherein the upper surface ofthe sealant layer (radially inward facing surface) further comprises anoutwardly facing detackifier coating since, as described in furtherdetail below, such a coating will generally be thin (e.g., less than 0.1mm, less than 0.05 mm). In certain embodiments of the first-fourthembodiments, the thickness of the sealant layer across its width variesby no more than 10%, no more than 5%, no more than 3%, or even no morethan 2%. In other words, the thickness of such a sealant layer issubstantially consistent across its width and measurements taken at fiveor more places across its width having a thickness (according to one ofthe foregoing sizes) vary by no more than 10%, no more than 5%, no morethan 3%, or even no more than 2%. In other embodiments of thefirst-fourth embodiments, the thickness of the sealant layer across itswidth varies with a center portion being the thickest; in certain suchembodiments the center portion has a thickness according to one of theranges or values discussed above. In certain embodiments of thefirst-fourth embodiments wherein the thickness of the sealant layervaries across its width and the center portion has a thickness accordingto one the ranges or values discussed above, the thickness tapers on anoutward basis with the outer edges of the sealant layer being thethinnest. In certain embodiments, the center portion of the sealantlayer comprises 25-75% (e.g., 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%,65%, 70%, 75%) of the overall width of the sealant layer and in otherembodiments 40-60% of the overall width and includes thinner edges oneach side of the center portion. In certain embodiments of thefirst-fourth embodiments, the center portion may constitute an innerportion having thinner edges on each side of the inner portion but maynot be centered (e.g., the width of each edge portion is notequivalent).

In certain embodiments of the first embodiment, the sealant layer thatis provided has a width that varies by no more than 5% from the width ofthe radially inward facing surface of the inner liner of the tire asmeasured from belt-edge-to-belt-edge. Utilizing such a sealant layer canbe advantageous in that only one strip (or circumferential revolution)of sealant layer need be used to adhere to the inner layer of the tirethereby avoiding the use of thinner strips of sealant which requiremultiple strips or must at least be applied in multiple circumferentialrevolutions around the inner liner surface to sufficiently cover theinner liner surface (e.g., the width of the radially inward facingsurface of the inner liner as measured from belt-edge-to-belt-edge or awidth no more than 5% less thereof). In certain embodiments of thesecond-fourth embodiments, the sealant layer of the tire has a widththat varies by no more than 5% from the width of the radially inwardfacing surface of the inner liner of the tire as measured frombelt-edge-to-belt-edge. In certain embodiments of the first-fourthembodiments, the sealant layer has a width that varies by no more than4%, no more than 3%, no more than 2%, or no more than 1% from the widthof the radially inward facing surface of the inner liner of the tire asmeasured from belt-edge-to-belt-edge. In certain embodiments of thefirst-fourth embodiments, the sealant layer has a width equivalent tothe width of the radially inward facing surface of the inner liner ofthe tire as measured from belt-edge-to-belt-edge. In certain embodimentsof the first-fourth embodiments, the sealant layer has a width that issuitable for use with a passenger tire such as a width of 5-25 cm (e.g.,5, 8, 10, 12, 15, 17, 20, 22, 25 cm) or 8-20 cm. In certain embodimentsof the first-fourth embodiments, the sealant layer has a width that issuitable for use with a truck or bus tire such as a width of 15-60 cm(e.g., 15, 20, 25, 30, 35, 40, 45, 50, 55, 60 cm) or 20-50 cm.

According to the first-fourth embodiments, the sealant layer comprises amixture of ingredients as follows: (i) 100 parts of at least one rubberselected from the group consisting of butyl rubber (optionallyhalogenated), natural rubber, polyisoprene, polybutadiene rubber,styrene-butadiene rubber, styrene-butadiene-isoprene rubber,isoprene-butadiene rubber, polychloroprene rubber, EPDM, nitrile rubber,polyisobutylene and combinations thereof; (ii) 90-500 phr of at leastone tackifier; (iii) optionally one or more extenders in a total amountof no more than 55 phr; (iv) optionally at least one hydroscopicsubstance in an amount of 0.5 to 10 phr; and (v) a cure package. Asdiscussed in more detail herein, according to certain embodiments of thefirst-fourth embodiments, the sealant layer may further comprise(include) one or more of: a barrier layer upon its lower surface (whichbecomes radially outward facing), a removable backing upon its lowersurface (which becomes radially outward facing), or a detackifiercoating upon its upper surface.

In preferred embodiments of the first-fourth embodiments, thecomposition of the sealant layer including its upper surface (whichbecomes radially inward facing), its lower surface (which becomesradially outward facing) as well as the portion therebetween has auniform composition of ingredients. In other words, in such embodiments,the upper surface (which becomes radially inward facing), the lowersurface (which becomes radially outward facing) as well as the portionof the sealant layer therebetween the surfaces are made from the samemixture of ingredients. (The upper surface of the sealant layer, lowersurface of the sealant layer and portion therebetween can be referred toas the rubber portion of the sealant layer.) In such embodiments, anyadditional component of the sealant layer that is present such as thebarrier layer, the detackifier coating, and the removable backing willhave a composition which differs from that of the rubber portion. Asdiscussed in further detail herein, in certain embodiments of thefirst-fourth embodiments less than the entire rubber portion of thesealant layer is cured (e.g., the upper surface of the sealant layer maybe cured and the remainder (the lower surface and the portion betweenthe upper and lower surfaces) may be uncured; in such embodiments eventhough the portions of the sealant layer are in different forms (i.e.,cured versus uncured) their composition or the mixture of ingredientsfrom which they are made can be considered to be the same.

The mixture of ingredients which comprises the sealant layer may beprepared using standard mixing processes. Various mixing processes canbe used for combining the ingredients of the rubber portion. In certainembodiments, the mixture of ingredients that comprises the sealant layeris prepared by a process that comprises: providing ingredients includingrubber(s), tackifiers, any extender, and any hydroscopic substance, andmixing to form a masterbatch which results in a mixture used to form therubber portion. In certain such embodiments, a final batch is preparedfrom the masterbatch by adding the cure package ingredients thereto andmixing, resulting in the final mixture used to form the sealant layer.

In certain embodiments, more than one masterbatch stage may be utilized,e.g., an initial masterbatch followed by at least one additionalmasterbatch step. The foregoing process options may also (optionally) beutilized in preparing the mixture of ingredients that comprises thesealant layer.

The preparation of the masterbatch(es) and the final batch may generallyinvolve mixing together the ingredients for the rubber portion (asdisclosed above) by methods known in the art, such as, for example, bykneading the ingredients together in a Banbury mixer, kneader, or on amilled roll. The term masterbatch as used herein is intended to refer toa non-productive mixing stage, which is known to those of skill in theart and generally understood to be a mixing stage where no vulcanizingagents or vulcanization accelerators are added. The term final batch asused herein is intended to refer to a productive mixing stage, which isalso known to those of skill in the art and generally understood to bethe mixing stage where the vulcanizing agents and vulcanizationaccelerators are added into the mixture.

In certain embodiments, the mixture of ingredients that comprises thesealant layer of the first-fourth embodiments is prepared by a processincluding master batch mixing stage(s) conducted at a temperature ofabout 80° C. to about 150° C. (e.g., 80, 90, 100, 110, 120, 130, 140 or150° C.). In certain embodiments, the mixture of ingredients thatcomprises the sealant layer of the first-fourth embodiments is preparedby a process that also includes a final mixing stage conducted at atemperature below the vulcanization temperature in order to avoidunwanted pre-cure of the sealant composition. Therefore, the temperatureof the productive (or final) mixing stage should not exceed about 160°C. (e.g., 80, 90, 100, 110, 120, 130, 140, 150, 160° C.) and istypically about 80° C. to about 150° C. In certain embodiments, themixture of ingredients that comprises the sealant layer of thefirst-fourth embodiments is prepared by a process including at least twomaster batch mixing stages (which may be conducted at the foregoingtemperature).

-   Rubber

As discussed above, according to the first-fourth embodiments, thesealant layer comprises a mixture of ingredients including 100 parts ofat least one rubber selected from the group consisting of butyl rubber(optionally halogenated), natural rubber, polyisoprene, polybutadienerubber, styrene-butadiene rubber, styrene-butadiene-isoprene rubber,isoprene-butadiene rubber, polychloroprene rubber, EPDM, nitrile rubber,polyisobutylene and combinations thereof. In certain embodiments of thefirst-fourth embodiments, any polybutadiene rubber used in the mixturefor the sealant layer preferably has at least 90% cis bond content, evenmore preferably at least 95% cis bond content. Polyisobutylenes suitablefor use as a rubber in the mixture of ingredients comprising the sealantlayer of the first-fourth embodiments are those with a number averagemolecular weight (Mn) of greater than 100,000 grams/mole, preferably atleast 250,000 grams/mole; in certain such embodiments, thepolyisobutylene rubber has a Mn of up to 5,000,000. Generally,polyisobutylenes having lower Mn values exhibit less elastomeric orrubber-like properties and instead have properties more suitable for useas a tackifier.

By stating that the at least one rubber may include butyl rubber(optionally halogenated) is meant that the at least one rubber maycomprise, at least one butyl rubber, at least one halogenated butylrubber, or a combination thereof. Butyl rubber is a copolymer ofisobutylene and a small amount of a diene-based monomer, typicallyisoprene or para-methylstyrene. The polymer chains of butyl rubbertherefore typically have a highly saturated backbone. Butyl rubbertypically contains more than about 90% isobutylene and less than about10% diene-based monomer (e.g., isoprene or para-methylstyrene) by weightin the copolymer, including about 90-99.5% isobutylene and about 10 toabout 0.5% diene-based monomer, about 95-99.5% isobutylene and about5-0.5% diene-based monomer, about 96-99% isobutylene and about 4-1%diene-based monomer, about 97-98.5% isobutylene and about 1.5-3%diene-based monomer, and including about 98% isobutylene and about 2%diene-based monomer by weight in the copolymer. Typically, thediene-based mer (e.g., isoprenyl or para-methylstyrenyl) units aredistributed randomly in the polymer chains of butyl rubber. Non-limitingexamples of suitable butyl rubbers for use as the at least one rubber ofthe mixture comprising the sealant layer according to certainembodiments of the first-fourth embodiments disclosed herein include,but are not limited to, butyl rubber, chlorobutyl rubber, bromobutylrubber, fluorobutyl rubber, iodobutyl rubber, copolymers thereof, andcombinations thereof. In certain embodiments of the first-fourthembodiments, the at least one rubber comprises bromobutyl rubber. Inother embodiments of the first-fourth embodiments, the at least onerubber comprises non-halogenated butyl rubber; in certain suchembodiment, no halogenated butyl rubber is included in the rubber of themixture comprising the sealant layer.

In certain embodiments of the first-fourth embodiments, the 100 parts ofat least one rubber in the mixture of ingredients comprising the sealantlayer comprises a majority by weight of butyl rubber (optionallyhalogenated), EPDM, or a combination thereof. In certain embodiments ofthe first-fourth embodiments, the 100 parts of at least one rubber inthe mixture of ingredients comprising the sealant layer comprises atleast 60 parts of butyl rubber (optionally halogenated), EPDM, or acombination thereof; alternatively stated such a mixture can bedescribed as having at least 60% by weight of the rubber comprisingbutyl rubber (optionally halogenated), EPDM, or a combination thereof.In certain embodiments of the first-fourth embodiments, the 100 parts ofat least one rubber in the mixture of ingredients comprising the sealantlayer comprises at least 70 parts, at least 80 parts, at least 85 parts,at least 90 parts, at least 95 parts, at least 98 parts, or at least 99parts of butyl rubber (optionally halogenated), EPDM, or a combinationthereof. In certain embodiments of the first-fourth embodiments, theentire 100 parts of at least one rubber in the mixture of ingredientscomprising the sealant layer comprises butyl rubber (optionallyhalogenated), EPDM, or a combination thereof. In certain embodiments ofthe first-fourth embodiments according to the foregoing (i.e., wherein60 parts or more of the rubber comprises butyl rubber, halogenated butylrubber, EPDM rubber, or a combination thereof), the 90-300 phr of atleast one tackifier is selected from polybutene (as described furtherbelow), low molecular weight polyisobutylene (as described furtherbelow), liquid EPDM (as described further below) or a combinationthereof.

In certain embodiments of the first-fourth embodiments, the 100 parts ofat least one rubber in the mixture of ingredients comprising the sealantlayer includes no more than 20 parts, no more than 10 parts, or no morethan 5 parts of nitrile rubber. In certain embodiments of thefirst-fourth embodiments, the 100 parts of at least one rubber in themixture of ingredients comprising the sealant layer includes 0 parts or0 phr of nitrile rubber (i.e., the rubber does not include nitrilerubber and, hence, the overall mixture can be described as free ofnitrile rubber). Use of large amounts of nitrile rubber in the sealantlayer may inhibit its sealant properties.

In certain embodiments of the first-fourth embodiments, the 100 parts ofat least one rubber in the mixture of ingredients comprising the sealantlayer includes less than 10 parts, less than 5 parts, less than 1 part,or even 0 parts of any block copolymer elastomer. As used herein, thephrase block copolymer elastomer includes polymers comprising at leastone segment of a styrenic polymer and at least one segment of anelastomeric saturated olefin polymer (non-limiting examples of whichinclude the G1600 and G1700 rubbers available from Kraton Polymers, LLCof Houston, Texas).

-   Tackifier

As discussed above, according to the first-fourth embodiments, thesealant layer comprises a mixture of ingredients including 90 to 500 phr(e.g., 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210,220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350,360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, or500 phr) of at least one tackifier. According to the first-fourthembodiments, one more or more than tackifier may be utilized. In certainembodiments of the first-fourth embodiments, the sealant layer comprisesa mixture of ingredients including 110-210 phr (e.g., 110, 120, 130,140, 150, 160, 170, 180, 190, 200, 210 phr) of at least one tackifier or120-190 phr (e.g., 120, 130, 140, 150, 160, 170, 180, 190 phr) of atleast one tackifier. In certain embodiments of the first-fourthembodiments, the sealant layer comprises a mixture of ingredientsincluding 300-450 phr (e.g., 300, 310, 320, 330, 340, 350, 360, 370,380, 390, 400, 410, 420, 430, 440, or 450 phr) of at least onetackifier.

The particular tackifier or tackifiers utilized in the mixturecomprising the sealant layer of the first-fourth embodiments may vary.As used herein, the term tackifier encompasses hydrocarbons resins(e.g., natural resins, synthetic resins, and combinations thereof) aswell as low molecular weight polymer or oligomers. In certainembodiments of the first-fourth embodiments, when a low molecular weightpolymer or oligomer is utilized as a tackifier in the mixture comprisingthe sealant layer, such an ingredient can be understood as having aweight average molecular weight or Mw of 700-150,000 grams/mole, a Mw of1000-100,000 grams/mole, or a Mw of 1,500-75,000 grams/mole; and/or a Mnof 500-100,000 grams/mole, a Mn of 700-90,000 grams/mole, or a Mn of900-50,000 grams/mole. Mw and Mn values referred to herein can bedetermined by gel permeation chromatography (GPC) calibrated withpolystyrene standards.

In certain embodiments of the first-fourth embodiments, the at least onetackifier of the sealant layer comprises at least one low molecularweight polymer or oligomer comprised of aliphatic monomer(s), aromaticmonomer(s), or a combination thereof. One or more of each type ofmonomer may be used, as well as combinations thereof. The aliphaticmonomer may be a linear, branched or cycloaliphatic monomer. Exemplaryaliphatic monomers include: C4 paraffins, C5 paraffins, C6 paraffins,olefins, conjugated diener, and combinations thereof. More specificexamples of aliphatic monomers include: 1,3-butadiene; butene;isobutylene; 1,3-pentadiene; 1,4-pentadiene; cyclopentane; 1-pentene;2-pentene; 2-methyl-1-pentene; 2-methyl-2-butene; 2-methyl-2-pentene;isoprene; cyclohexane; 1,3-hexadiene; 1,4-hexadiene; cyclopentadiene;dicyclopentadiene; and combinations thereof. The aromatic monomer may beoptionally substituted with one or more hydrocarbon groups. Exemplaryaromatic monomers include: styrene, indene, C8 aromatics, C9 aromatics;C10 aromatics; and combinations thereof. In certain embodiments of thefirst-fourth embodiments, the at least one tackifer includes at leastone low molecular weight polymer or oligomer selected from polybutene(as described in further detail below), low molecular weightpolyisobutylene (as described in further detail below), liquid EPDM (asdescribed in further detail below), liquid or low molecular weightpolyisoprene (as described in further detail below), liquid or lowmolecular weight styrene-butadiene (as described in further detailbelow), liquid or low molecular weight polybutadiene (as described infurther detail below), or a combination thereof.

In certain embodiments of the first-fourth embodiments, the at least onetackifier comprises (includes) liquid EPDM. Liquid EPDMs suitable foruse as a tackifer in the first-fourth embodiments will generally beliquid or flowable at room temperature (23° C.). Suitable liquid EPDMsfor use as a tackifer are commercially available, including, but notlimited to, Trilene® liquid EPDMs from Lion Elastomers (e.g., Trilene®67, Trilene® 77). In certain embodiments of the first-fourthembodiments, the liquid EPDM has a viscosity of 50,000 to 150,000centipoise, or 90,000 to 130,000 centipose (Brookfield viscosity,measured at 100° C.). In certain embodiments of the first-fourthembodiments, the liquid EPDM has a Mw of 20,000 to 100,000 grams/mole(e.g., 20,000; 25,000; 30,000; 40,000; 50,000; 60,000; 70,000; 80,000;90,000; 100,000), or 25,000 to 75,000 grams/mole.

In certain embodiments of the first-fourth embodiments, the at least onetackifier comprises (includes) liquid or low molecular weightpolyisoprene. In certain embodiments of the first-fourth embodiments,the liquid or low molecular weight polyisoprene has a Mw of 15,000 to100,000 grams/mole (e.g., 15,000; 20,000; 30,000; 40,000; 50,000;60,000; 70,000; 80,000; 90,000; 100,000), or 25,000 to 80,000grams/mole. Liquid or low molecular weight polyisoprenes suitable foruse as a tackifer are commercially available, including, but not limitedto, Isolene® polyisoprenes (e.g., Isolene® 40-S, Isolene® 400-S) fromRoyal Adhesives & Sealant,; DPR® polyisoprenes (e.g., DPR® 35, DPR® 40,and DPR® 75) from DPR Industries; and from Kuraray Co., Ltd. (e.g.,LIR-30 and LIR-50).

In certain embodiments of the first-fourth embodiments, the least onetackifier comprises (includes) liquid or low molecular weightstyrene-butadiene. In certain embodiments of the first-fourthembodiments, the liquid or low molecular weight styrene-butadiene has aMw of 5,000 to 70,000 grams/mole (e.g., 5,000; 7,500; 10,000; 20,000;30,000; 40,000; 50,000; 60,000; 70,000) or 7,500 to 50,000 grams/mole.Liquid or low molecular weight styrene-butadienes suitable for use as atackifier are commercially available, including, but not limited to fromKuraray Co., Ltd. (e.g., L-SBR-820 and L-SBR-841).

In certain embodiments of the first-fourth embodiments, the least onetackifier comprises (includes) liquid or low molecular weightpolybutadiene. In certain embodiments of the first-fourth embodiments,the liquid or low molecular weight polybutadiene has a Mw of 5,000 to70,000 grams/mole (e.g., 5,000; 7,500; 10,000; 20,000; 30,000; 40,000;50,000; 60,000; 70,000) or 7,500 to 50,000 grams/mole. Liquid or lowmolecular weight polybutadienes suitable for use as a tackifier arecommercially available, including, but not limited to from Kuraray Co.,Ltd. (e.g., LBR-307, LBR-305, and LBR-352). In certain embodiments ofthe first-fourth embodiments, the at least one tackifier comprises(includes) a low molecular weight polybutadiene which has beenfunctionalized with a polar group-containing compound. In otherembodiments of the first-fourth embodiments, the at least one tackifiercomprises (includes) another (i.e., other than polybutadiene) lowpolymer (as discussed above) which has been functionalized with apolar-group-containing compound; as a non-limiting example the lowmolecular weight polyisoprenes discussed above could be functionalizedwith a polar group-containing compound. Non-limiting examples ofsuitable polar group-containing compounds include anhydride-containingcompounds (e.g., maleic anhydride or succinic anhydride), carboxylicacid-containing compounds, phosphorous-containing compounds (e.g.,phosphonic acid or derivates thereof including phosphate compounds), andnitrogen-containing compounds (e.g., containing an substituted orunsubstituted amino group, an amide residue, an isocyanate group, animidazolyl group, an indolyl group, a nitrile group, a pyridyl group,and a ketimine group). The foregoing substituted or unsubstituted aminogroup should be understood to include a primary alkylamine, a secondaryalkylamine, or a cyclic amine, and an amino group derived from asubstituted or unsubstituted imine. Various of the foregoing polargroup-functionalized low molecular weight polymers are commerciallyavailable, non-limiting examples of which include polybutadiene productssold by Synthomer under the tradename Lithene® (e.g., Lithene® UltraAL-15MA, Lithene® Ultra N4-5000-10MA, Lithene® Ultra N4-5000-10MA, andLithene® Ultra-PM4-7.5MA) and polyisoprenes sold by Kuraray under thedesignations LIR-403 and LIR-410. In certain embodiments of thefirst-fourth embodiments, the low molecular weight polymer is a maleicanhydride functionalized polybutadiene having a Mn of 1200 to 10,000grams/mole (e.g., 1200, 1500, 1800, 2000, 2500, 3000, 3500, 4000, 4500,5000, 5500, 6000, 6500, 7000, 7500, 8000, 8500, 9000, 9500, or 10,000grams/mole), or 1200 to 5,000 grams/mole (e.g., 1200, 1500, 1800, 2000,2500, 3000, 3500, 4000, 4500, 5000, grams/mole). In certain embodimentsof the first-fourth embodiments, the low molecular weight polymer is amaleic anhydride functionalized polybutadiene having a viscosity at 25°C. of 10-1000 dPa·s (e.g., 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 200,300, 400, 500, 600, 700, 800, 900 or 1000 dPa·s. When a maleic anhydridefunctionalized polybutadiene is used, the amount of maleic anhydridefunctionalization may be measured in terms of how many parts of maleicanhydride are adducted with the polybutadiene. In certain embodiments ofthe first-fourth embodiments, the low molecular weight polymer is amaleic anhydride functionalized polybutadiene having 5-25 parts (e.g.,5, 10, 15, 20, or 25 parts) adducted maleic anhydride, or 10-20 partsadducted maleic anhydride. In certain embodiments of the first-fourthembodiments, the maleic anhydride functionalized polybutadiene (oranother polar group functionalized low molecular weight polymer) ispresent in the mixture of the sealant layer in an amount of 5-100 phr(e.g., 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80,85, 90, 95, or 100 phr) or more preferably 10-50 phr (e.g., 5, 10, 15,20, 25, 30, 35, 40, 45, or 50 phr). The use of a low molecular weightpolymer which has been functionalized with a polar group-containingcompound (e.g., maleic anhydride functionalized polybutadiene), providesmore favorable interaction with the metal surface of a nail which haspunctured a tire containing the sealant layer. Various metals are knownto be in common use in nails, including, but not limited to steel,stainless steel, aluminum, titanium, zinc, hafnium, as well as theremaining 1^(st) and 2^(nd) row transition metals; it is believed thatthe use of a low molecular weight polymer which has been functionalizedwith a polar group-containing compound will provide more favorableinteraction with a nail containing any one or more of these metals.

In certain embodiments of the first-fourth embodiments, the least onetackifier comprises (includes) a low molecular polymer which is acopolymer of at least one polar monomer and at least one non-polarmonomer; such a copolymer can be referred to as a low molecular weightpolar/non-polar copolymer or simply as a polar/non-polar copolymer. Incertain embodiments of the first-fourth embodiments, the tackifierincludes a polar/non-polar copolymer having a molecular weight Mw of40,000 to 120,000 grams/mole (e.g., 40,000; 50,000; 60,000; 70,000;80,000; 90,000; 100,000; 110,000; or 120,000 grams/mole), or a Mw of50,000 to 100,000 (e.g., 50,000; 60,000; 70,000; 80,000; 90,000; or100,000; grams/mole). In certain embodiments of the first-fourthembodiments, the non-polar monomer comprises a diene. Non-limitingexamples of suitable diener include vinyl, ethylene, propylene, andoctadecene. Non-limiting examples of polar monomers which may be used incombination with the non-polar monomer or diene include, but are notlimited to, acetates (such as vinyl acetate), anhydrides (such as maleicanhydride), N-containing moieties including both aromatic andnon-aromatic rings (such as pyrrolidones, pyridines, pyridine N-oxide),or ketones (such as methyl ketone). Exemplary polar/non-polar copolymersthat may be suitable for use in the tackifier include, but are notlimited to, poly(ethylene-co-vinylacetate), poly(vinyl methyl ketone),poly(maleic anhydride 1-octadecene), poly(vinylpyridine),poly(2-vinylpyridine N-oxide), poly(4-vinylpyridine N-oxide),poly(N-vinylpyrrolidone), and combinations thereof. In certainembodiments of the first-fourth embodiment, the polar/non-polarcopolymer is present in the mixture of the sealant layer in an amount of5-100 phr (e.g., 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70,75, 80, 85, 90, 95, or 100 phr) or more preferably 10-50 phr (e.g., 5,10, 15, 20, 25, 30, 35, 40, 45, or 50 phr).

In certain embodiments of the first-fourth embodiments, the at least onetackifier comprises (includes) polybutene. In certain embodiments of thefirst-fourth embodiments, up to 200 phr of the at least one tackifiercomprises polybutene. In certain embodiments of the first-fourthembodiments, polybutene is present in an amount of up to 200 phr of theup to 300 phr of tackifier present in the mixture that comprises thesealant layer. In certain embodiments of the first-fourth embodiments, amajority by weight (e.g., at least 51%, at least 60%, at least 70%, atleast 80%, at least 90%, at least 95%, at least 98%, or even 100% byweight) of the tackifier is polybutene. Suitable polybutenes for use asa tackifier are commercially available, including, but not limited to,Indopol® polybutenes from INEOS Oligomers (e.g., H-100, H-300, H-1500,H-1900). In certain embodiments of the first-fourth embodiments whereinthe tackifier includes polybutene, the polybutene has a Mn of 500-10,000grams/mole or 500-5,000 grams/mole.

In certain embodiments of the first-fourth embodiments, the at least onetackifier comprises (includes) low molecular weight polyisobutylene. Asused herein, the phrase low molecular weight polyisobutylene (LMWpolyisobutylene) refers to polyisobutylenes having a Mn of 100,000grams/mole or less, and in certain embodiments a Mn of less than 50,000grams/mole. In certain embodiments of the first-fourth embodiments, LMWpolyisobutylene is included in the at least one tackifier in an amountup to 30% by weight of the tackifier, up to 25% by weight of thetackifier, up to 20% by weight of the tackifier, up to 15% by weight ofthe tackifier, or up to 10% by weight of the tackifier; in certain suchembodiments, the LMW polyisobutylene is used in combination withpolybutene, optionally in one of the amounts discussed above. In thoseembodiments of the first-fourth embodiments wherein LMW polyisobutyleneis included in the at least one tackifier, phr amounts of the LMWpolyisobutylene can be calculated by multiplying the total phr oftackifier by the weight percentage made up of LMW polyisobutylene (e.g.,if 90 phr of total tackifier are present then exemplary amounts of LMWpolyisobutylene would be up to 27 phr, up to about 22 phr, up to 18 phr,up to about 13 phr, or up to 9 phr, and if 300 phr of total tackifierare present then exemplary amounts of LMW polyisobutylene would be up to90 phr, up to 75 phr, up to 60 phr, up to 45 phr, or up to 30 phr) andsuch amounts and ranges should be considered to be fully disclosedherein. Suitable LMW polyisobutylenes for use as a tackifier arecommercially available, including, but not limited to Oppanol® B seriespolyisobutylenes from BASF (e.g., B10, B15). In certain embodiments ofthe first-fourth embodiments, wherein the tackifier includes LMWpolyisobutylene, the LMW polyisobutylene has a Mn of 20,000 to 100,000grams/mole, 30,000 to 90,000 grams/mole, or 30,000 to 50,000 grams/mole.

In certain embodiments of the first-fourth embodiments, the at least onetackifier of the mixture that comprises the sealant layer comprises(includes) at least one resin selected from the group consisting ofphenolic resins, aliphatic resins, cycloaliphatic resins, aromaticresins, terpene resins, guayule resins, and combinations thereof. Incertain embodiments of the first-fourth embodiments, at least one of theforegoing resins is used in combination with polybutene as tackifiers inthe mixture that comprises the sealant layer. In certain embodiments ofthe first-fourth embodiments, at least one of the foregoing resins isused in combination with polybutene and LMW polyisobutylene astackifiers in the mixture that comprises the sealant layer. In certainembodiments of the first-fourth embodiments, at least one of theforegoing resins is included in the at least one tackifier in a totalamount up to 20% by weight of the tackifier, up to 15% by weight of thetackifier, up to 10% by weight of the tackifier, or up to 5% by weightof the tackifier; in certain such embodiments, the at least one resin isused in combination with polybutene or in combination with polybuteneand LMW polyisobutylene as tackifiers.

In certain embodiments of the first-fourth embodiments, the at least onetackifier comprises at least one resin selected from: (1) phenolicresins such as phenol novolak resins, phenol-formaldehyde resins,resorcinol-formaldehyde resins, reactive resol resins (which can reactwith unsaturation in an elastomer or rubber to contribute tocrosslinking), and reactive novolak type phenol-formaldehyde resins(which can crosslink with methylene donors); (2) aliphatic resins suchas such as C5 and/or C9 fraction homopolymer or copolymer resins,optionally in combination with one or more of e.g., cycloaliphatic,aromatic, hydrogenated aromatic, or terpene resins and/or optionallypartially or fully hydrogenated; (3) cycloaliphatic resins (such ascyclopentadiene (“CPD”) homopolymer or copolymer resins, anddicyclopentadiene (“DCPD”) homopolymer or copolymer resins), optionallyin combination with one or more of aliphatic, aromatic, hydrogenatedaromatic, or terpene resins, and/or optionally partially or fullyhydrogenated; (4) aromatic resins (such as coumarone-indene resins andalkyl-phenol resins as well as vinyl aromatic homopolymer or copolymerresins such as those including one or more of the following monomers:alpha-methylstyrene, styrene, ortho-methylstyrene, meta-methylstyrene,para-methylstyrene, vinyltoluene, para(tert-butyl)styrene,methoxystyrene, chlorostyrene, hydroxystyrene, vinylmesitylene,divinylbenzene, vinylnaphthalene or any vinyl aromatic monomer resultingfrom C9 fraction or C8-C10 fraction), optionally in combination with oneor more of aliphatic, cycloaliphatic, hydrogenated aromatic, or terpeneresins, and/or optionally partially or fully hydrogenated; (5) terpeneresins (such as alpha-pinene resins, beta-pinene resins, limonene resins(e.g., L-limonene, D-limonene, dipentene which is a racemic mixture ofL- and D-isomers), beta-phellandrene, delta-3-carene, anddelta-2-carene), optionally in combination with one or more ofaliphatic, cycloaliphatic, aromatic, or hydrogenated aromatic resins,and/or optionally partially or fully hydrogenated; or (6) guayuleresins. In certain embodiments of the first-fourth embodiments, morethan one of a particular type of the foregoing resins are utilized astackifiers and in other embodiments more than one each of at least twoparticular types of the foregoing resins are utilized as tackifiers. Incertain embodiments of the first-fourth embodiments, the tackifiercomprises (includes) a phenolic resin.

-   Extender

As discussed above, according to the first-fourth embodiments, themixture that comprises the sealant layer may optionally include one ormore extenders. According to the first-fourth embodiments, one or morethan one extender may be utilized (e.g., two, three, four, or more). Bystating that the mixture comprising the sealant layer may optionallyinclude one or more extenders is meant that in certain embodiments, themixture of the sealant layer includes one or more extenders and in otherembodiments the mixture of the sealant layer includes no extenders. Asused herein, the term extender refers to a generally inert ingredientused to provide bulk to the mixture that comprises the sealant layer. Incertain embodiments according to the first-fourth embodiments, the oneor more extenders are non-reinforcing extenders which are generally lessexpensive than reinforcing extenders. In certain embodiments accordingto the first-fourth embodiments wherein at least one extender ispresent, the total amount of reinforcing extender is no more than 20phr, no more than 15 phr, no more than 10 phr, no more than 5 phr oreven 0 phr. Limiting the amount of reinforcing extender utilized (oreven entirely avoiding the use of reinforcing extenders) may bepreferable in certain embodiments of the first-fourth embodiments inorder to avoid unduly increasing the viscosity of the sealant layerand/or an increased modulus thereof which can adversely impact sealingperformance. In other embodiments according to the first-fourthembodiments, the one or more extenders may include at least onereinforcing extender. As used herein, the term reinforcing extenderrefers to an ingredient which when added to a rubber compositionprovides an improvement in one or more properties such as abrasionresistance, tear strength, or aging resistance. The term non-reinforcingextender can also be understood to refer to a particulate material thathas a nitrogen surface area of less than about 20 m²/g (including lessthan 20 m²/g), and in certain embodiments less than about 10 m²/g(including less than 10 m²/g); reinforcing extenders will have surfaceareas higher than the foregoing. The nitrogen surface area ofparticulate extender materials can be determined according to variousstandard methods (including ASTM D6556 or D3037). In certain embodimentsof the first-fourth embodiments disclosed herein, the termnon-reinforcing extender is additionally or alternatively used to referto a particulate material that has a particle size of greater than about1000 nm (including greater than 1000 nm); reinforcing extenders willhave particle sizes less than the foregoing.

In those embodiments of the first-fourth embodiments wherein the mixturethat comprises the sealant layer includes one or more extenders, thetotal amount of extender(s) may vary. In certain embodiments of thefirst-fourth embodiments, the mixture that comprises the sealant layerincludes one or more extenders in a total amount of no more than 55 phr(e.g., 1 phr, 5 phr, 10 phr, 15 phr, 20 phr, 25 phr, 30 phr, 35 phr, 40phr, 45 phr, 50 phr, or 55 phr) or 1-55 phr. In other embodiments of thefirst-fourth embodiments, the mixture that comprises the sealant layerincludes one or more extenders in a total amount of no more than 35 phr(e.g., 1 phr, 5 phr, 10 phr, 15 phr, 20 phr, 25 phr, 30 phr, 35 phr).Limiting the total amount of extender (even if mostly or allnon-reinforcing extender(s) are utilized) may be preferable in certainembodiments of the first-fourth embodiments in order to avoid undulyincreasing in the viscosity of the sealant layer and/or an increasedmodulus thereof which can adversely impact sealing performance.

In those embodiments of the first-fourth embodiments wherein the mixturethat comprises the sealant layer includes one or more extenders, theparticular extender or extenders utilized may vary. In certainembodiments of the first-fourth embodiments, the mixture that comprisesthe sealant layer includes one or more extenders selected from: carbonblack, silica, talc, clay, graphite, alumina (Al₂O₃), aluminum hydrate(Al₂O₃H₂O), aluminum hydroxide (Al(OH)₃), aluminum carbonate(Al₂(CO₃)₂), aluminum nitride, aluminum magnesium oxide (MgOAl₂O₃),pyrofilite (Al₂O₃ 4 SiO₂·H₂O), bentonite (Al₂O₃·4 SiO₂·2 H₂O), boronnitride, silicon nitride, aluminum nitride, mica, kaolin, glass balloon,glass beads, calcium oxide (CaO), calcium hydroxide (Ca(OH)₂), calciumcarbonate (CaCO₃), magnesium hydroxide (MH(OH)₂), magnesium oxide (MgO),magnesium dioxide, magnesium carbonate (MgCO₃), titanium oxide, titaniumdioxide, potassium titanate, barium sulfate, zirconium oxide (ZrO₂),zirconium hydroxide [Zr(OH)₂·n H₂O], zirconium carbonate [Zr(CO₃)₂],crystalline aluminosilicates, calcium silicates, starch, gypsum (calciumsulfate hydrate), fly ash, and combinations thereof; in certain suchembodiments, the total amount of such extender(s) is no more than 55phr, no more than 35 phr, 15-45 phr or 2-30 phr. Non-limiting examplesof silica fillers suitable for use as an extender in certain embodimentsof the first-fourth embodiments disclosed herein include, but are notlimited to, precipitated amorphous silica, wet silica (hydrated silicicacid), dry silica (anhydrous silicic acid), fumed silica, calciumsilicate and the like. Other suitable silica fillers for use in rubbercompositions of certain embodiments of first-fourth embodimentsdisclosed herein include, but are not limited to, aluminum silicate,magnesium silicate (Mg₂SiO₄, MgSiO₃ etc.), magnesium calcium silicate(CaMgSiO₄), calcium silicate (Ca₂SiO₄ etc.), aluminum silicate (Al₂SiO₅,Al₄·3 SiO₄·5 H₂O etc.), aluminum calcium silicate (Al₂O₃·CaO₂SiO₂,etc.), and the like. Among the listed silica fillers, precipitatedamorphous wet-process, hydrated silica fillers are preferred. In certainembodiments of the first-fourth embodiments wherein the mixture thatcomprises the sealant layer includes one or more extenders, the extendercomprises carbon black, clay, titanium dioxide, calcium carbonate,graphite, talc, or a combination thereof; in certain such embodiments,the total amount of such extender(s) is no more than 55 phr, no morethan 35 phr, 15-45 phr or 2-30 phr.

In those embodiments of the first-fourth embodiments wherein it isdesirable for the sealant layer to be black, the one or more extenderspreferably includes carbon black (non-reinforcing, reinforcing, or acombination thereof), in one of the foregoing amounts. Among the usefulcarbon blacks are furnace black, channel blacks, and lamp blacks. Morespecifically, examples of useful carbon blacks include super abrasionfurnace (SAF) blacks, high abrasion furnace (HAF) blacks, fast extrusionfurnace (FEF) blacks, fine furnace (FF) blacks, intermediate superabrasion furnace (ISAF) blacks, semi-reinforcing furnace (SRF) blacks,medium processing channel blacks, hard processing channel blacks andconducting channel blacks. Typical suitable reinforcing carbon black(s)for use in certain embodiments of the first-fourth embodiments disclosedherein are N-110, N-220, N-339, N-330, N-351, N-550, N-660, and N-700series, all as designated by ASTM D-1765-82a. The carbon blacks utilizedcan be in pelletized form or an unpelletized flocculent mass.Preferably, for more uniform mixing, unpelletized carbon black ispreferred. Non-reinforcing carbon black(s) can also be used as the oneor more extenders, in a total amount equating to one of the foregoingamounts) be utilized. Non-limiting examples of non-reinforcing carbonblacks include, but are not limited to, thermal blacks or the N9 seriescarbon blacks (also referred to as the N-900 series), such as those withthe ASTM designation N-907, N-908, N-990, and N-991. Various carbonblacks meeting the foregoing are commercially available, including butnot limited to Thermax® N990 carbon black from Cancarb Limited (MedicineHat, Alberta, Canada).

In those embodiments of the first-fourth embodiments wherein it isdesirable for the sealant layer to be non-black, the one or moreextenders preferably includes talc, titanium dioxide, or calciumcarbonate, in one of the foregoing amounts. The use of such extenderscan be sufficient to render the sealant layer white in color. In otherembodiments of the first-fourth embodiments wherein it is desirable forthe sealant layer to be non-black but a non-white color is preferred,one or more of talc, titanium dioxide, or calcium carbonate (in one ormore of the foregoing amounts) may be utilized in combination with oneor more pigments to achieve a non-black, non-white color such as red,blue, orange, yellow, green, purple, or pink.

In certain embodiments of the first-fourth embodiments, the one or moreextenders includes 1-10 phr (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10phr), preferably 3-8 phr of fumed silica. The presence of fumed silicacan advantageously increase the cold flow stability of the sealant layerwhich can result in reduced cold flow of the sealant layer at low shear(e.g., through an unplugged hole or puncture such as may be created whena nail is removed from the tire) at relatively low temperatures. Thereduced cold flow of the sealant layer is exhibited by a reducedtendency for the sealant layer to flow out of the unplugged hole orpuncture, as compared to a sealant layer having the same compositionexcept for lacking the fumed silica. The presence of fumed silica canalso advantageously maintain the high shear viscosity of the sealantcomposition at relatively low temperatures as well as performance atrelatively higher temperatures. Various types of fumed silicas arecommercially available and suitable for use in certain embodiments ofthe first-fourth embodiments. Non-limiting examples include fumedsilicas available from Evonik Industries under the Aerosil® tradename aswell as those available from Cabot under the Cab-O-Sil® tradename. Incertain embodiments of the first-fourth embodiments, the fumed silicamay be hydrophobic or hydrophilic, although hydrophobic fumed silicasare preferred. In certain embodiments of the first-fourth embodiments,the fumed silica has a BET surface area of 100-300 m²/g (e.g., 100, 120,140, 160, 180, 200, 220, 240, 260, 280, or 300 m²/g), or 150-250 m²/g(e.g., 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, or 250 m²/gand/or a pH of 3-9 (e.g., 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8,8.5, or 9) or 4-6 (e.g., 4, 4.5, 5, 5.5, or 6).

-   Hydroscopic Substance

As discussed above, according to the first-fourth embodiments, themixture that comprises the sealant layer optionally includes at leastone hydroscopic substance. As used herein, the term hydroscopic refersto a substance which is capable of adsorbing water in its various forms(e.g., moisture in the air). In certain embodiments of the first-fourthembodiments, the mixture that comprises the sealant layer includes atleast one hydroscopic substance. In other embodiments of thefirst-fourth embodiments, the mixture that comprises the sealant layerlacks any (i.e., contains 0 phr) of any hydroscopic substance. In thoseembodiments of the first-fourth embodiments wherein the mixture thatcomprises the sealant layer includes at least one hydroscopic substance,the amount and identity of the hydroscopic substance(s) may vary. Incertain embodiments of the first-fourth embodiments wherein the mixturethat comprises the sealant layer includes at least one hydroscopicsubstance, the total amount of hydroscopic substance(s) is 0.5 to 20 phr(e.g., 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, or 20 phr) or 0.5 to 10phr (e.g., 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 phr). In otherembodiments of the first-fourth embodiments wherein the mixture thatcomprises the sealant layer includes at least one hydroscopic substance,the total amount of hydroscopic substance(s) is 1 to 5 phr (e.g., 1, 2,3, 4, or 5 phr). In certain embodiments of the first-fourth embodiments,the mixture that comprises the sealant layer includes at least onehydroscopic substance selected from calcium oxide, anhydrous silica,anhydrous sodium sulfate, anhydrous calcium sulfate, zeolites, andcombinations thereof; in certain such embodiments, the total amount ofsuch hydroscopic substance(s) is 0.5 to 10 phr.

-   Cure Package

As discussed above, according to the first-fourth embodiments, themixture that comprises the sealant layer includes a cure package.According to the first-fourth embodiments, the ingredients of the curepackage may vary, but generally will include at least a vulcanizingagent such as sulfur and one or more vulcanization accelerators. Incertain embodiments of the first-fourth embodiments, the cure packageincludes at least one vulcanizing agent and at least one vulcanizingaccelerator, and optionally at least one of: at least one vulcanizingactivator (e.g., zinc oxide, stearic acid, and the like), at least onevulcanizing inhibitor, at least one anti-scorching agent, or at leastone crosslink initiator. Vulcanizing accelerators and vulcanizingactivators act as catalysts for the vulcanization agent.

Examples of suitable types of vulcanizing agents for use in the mixtureof ingredients that comprises the sealant layer according to thefirst-fourth embodiments, include but are not limited to, sulfur orperoxide-based curing components. Thus, in certain such embodiments, thecurative component includes a sulfur-based curative or a peroxide-basedcurative. Examples of specific suitable sulfur vulcanizing agentsinclude “rubbermaker's” soluble sulfur; sulfur donating curing agents,such as an amine disulfide, polymeric polysulfide or sulfur olefinadducts; and insoluble polymeric sulfur. Preferably, the sulfurvulcanizing agent is insoluble sulfur or a mixture of soluble andinsoluble polymeric sulfur. For a general disclosure of suitablevulcanizing agents and other components used in curing, e.g.,vulcanizing inhibitor and anti-scorching agents, one can refer toKirk-Othmer, Encyclopedia of Chemical Technology, 3rd ed., WileyInterscience, N.Y. 1982, Vol. 20, pp. 365 to 468, particularlyVulcanization Agents and Auxiliary Materials, pp. 390 to 402, which isincorporated herein by reference. Vulcanizing agents can be used aloneor in combination. Generally, according to certain embodiments of thefirst-fourth embodiments, the vulcanizing agents are used in an amountranging from 0.1 to 10 phr, including from 0.5 to 7.5 phr, includingfrom 0.5 to 5 phr, and preferably from 0.5 to 3.5 phr.

In certain embodiments of the first-fourth embodiments disclosed herein,the at least one vulcanization accelerator used in the cure package ofthe mixture that comprises the sealant layer is selected from at leastone of the following classes of vulcanization accelerators: thiurams,thioureas, dithiocarbamates, xanthates, or thiophosphates. In certainembodiments of the first-fourth embodiments, the at least onevulcanization accelerator comprises a thiazole, optionally incombination with one of more vulcanization accelerators from one or moreof the foregoing classes. Non-limiting examples of vulcanizingaccelerators that belong to the class of thiurams include: TMTM(tetramethyl thiuram monosulfide), TMTD (tetramethyl thiuram disulfide),DPTT (dipentamethylene thiuram tetrasulfide), TETD (tetraethyl thiuramdisulfide), TiBTD (tetraisobutyl thiuram disulfide), and TBzTD(tetrabenzyl thiuram disulfide). Non-limiting examples of vulcanizingaccelerators that belong to the class of thioureas include: ETU(ethylene thiourea), DPTU (N,N-diethyl thiourea), DETU(N,N-dibutylthiourea), and DBTU (diphenyl thiourea). Non-limitingexamples of vulcanizing accelerators that belong to the class ofdithiocarbamates include: ZDMC (zinc dimethyl dithiocarbamate), ZDEC(zinc diethyl dithiocarbamate), ZDBC (zinc dibutyl dithiocarbamate),ZEDC (zinc N-ethyl-dithiocarbamate), CDMC (copper dimethyldithiocarbamate) and ZBEC (zinc dibenzyl dithiocarbamate). Non-limitingexamples of vulcanizing accelerators that belong to the class ofxanthates include: ZIX (zinc isopropyl xanthate). Non-limiting examplesof vulcanizing accelerators that belong to the class of thiophosphatesinclude: ZBDP (Zinc-O,O-di-N-phosphorodithioate). Non-limiting examplesof vulcanizing accelerators that belong to the class of thiazolesinclude: MBT (2-mercaptobenzothiazole), MBTS (2,2-benzothiazoledisulfide), ZMBT (zinc 2-mercaptobenzothiazole) and CMBT (copper2-mercaptobenzothiazole). Additional examples of suitable vulcanizingaccelerators for use in certain embodiments of the first-fourthembodiments disclosed herein include, but are not limited to:sulfenamides (e.g., N-cyclohexyl-2-benzothiazole-sulfenamide (CBS),N-tert-butyl-2-benzothiazole-sulfenamide (TBBS), and the like);guanidine vulcanization accelerators (e.g., diphenyl guanidine (DPG) andthe like); and carbamate vulcanizing accelerators (e.g., zinc dibutyldithocarbamate (ZDBC), zinc dibenzyl dithiocarbamate (ZBEC), zincdiethyl dithiocarbamate (ZDEC), zinc dimethyl dithiocarbamate (ZDMC),zinc N-ethyl-dithiocarbamate (ZEDC), copper dimethyl diothiocarbmate(CDMC), and the like), and combinations thereof; such vulcanizationaccelerators can be used either alone, in combination, or in combinationwith one of the foregoing classes of vulcanization accelerators.Generally, according to certain embodiments of the first-fourthembodiments, the total amount of vulcanization accelerator (when used)ranges from 0.5 to 15 phr (e.g., 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,12, 13, 14, 15 phr), 0.5 to 10 phr, 1 to 5 phr, or 2 to 10 phr. Incertain embodiments of the first-fourth embodiments, the vulcanizingagent (when present) is used in an amount ranging from 0.1 to 10 phr(e.g., 0.1, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 phr), including from 0.1to 7.5 phr, including from 0.1 to 5 phr, and preferably from 0.1 to 3.5phr.

Vulcanizing activators are additives used to support vulcanization.Generally vulcanizing activators include both an inorganic and organiccomponent. Zinc oxide is the most widely used inorganic vulcanizationactivator. Various organic vulcanization activators are commonly usedincluding stearic acid, palmitic acid, lauric acid, and zinc salts ofeach of the foregoing. In certain embodiments of the first-fourthembodiments wherein the mixture that comprises the sealant layerincludes a cure package which comprises a vulcanizing activator, theamount of vulcanization activator used ranges from 0.1 to 10 phr (e.g.,0.1, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 phr), preferably 2 to 9(e.g., 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, or 9 phr)phr. In certain embodiments of the first-fourth embodiments, the mixturethat comprises the sealant layer includes a cure package which comprisesa vulcanizing activator selected from zinc oxide, stearic acid, palmiticacid, lauric acid, zinc salts of each of the foregoing acids, or acombination thereof; in certain such embodiments, the total amount ofvulcanizing activator(s) is one of the foregoing amounts. In otherembodiments of the first-fourth embodiments, the mixture that comprisesthe sealant layer includes a cure package that is devoid of anyvulcanizing activators (i.e., contains 0 phr of vulcanizing activator).

Vulcanization inhibitors are used to control the vulcanization processand generally retard or inhibit vulcanization until the desired timeand/or temperature is reached. Common vulcanization inhibitors include,but are not limited to, PVI (cyclohexylthiophthalmide) from Santogard.In certain embodiments of the first-fourth embodiments, the mixture thatcomprises the sealant layer includes a cure package which comprises avulcanization inhibitor in an amount of 0.1 to 3 phr, preferably 0.5 to2 phr; in certain such embodiments, the vulcanization inhibitor is PVI.In other embodiments of the first-fourth embodiments, the mixture thatcomprises the sealant layer includes a cure package that is devoid ofany vulcanization inhibitor (i.e., contains 0 phr of vulcanizationinhibitor).

In certain embodiments of the first-fourth embodiments, the mixture thatcomprises the sealant layer includes at least one crosslink initiator,e.g., as part of the cure package. As used herein, the term crosslinkinitiator refers to a compound which enhances or initiates carbon-carboncrosslinking between polymer chains of the at least one rubber, inparticular between polymer chains of halogenated butyl rubber. Thus, thecrosslinker initiator can also be referred to as a carbon-carboncrosslink initiator. In certain embodiments of the first-fourthembodiments, the mixture that comprises the sealant layer includes 1 to10 phr (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 phr), preferably 2 to 7phr of at least one crosslink initiator. Various compounds may besuitable for use as the crosslinker initiator, including, but notlimited to azo compounds (e.g., azoisobutyronitrile (AIBN)), peroxides(e.g., di-tert-butyl peroxide, quinoline compounds, or nitrones (e.g.,TEMPO). In certain embodiments of the first-fourth embodiments, the atleast one crosslink initiator includes a quinoline compound, preferablyselected from the group of hydrocarbyl-substituted quinolines. Aquinoline compound can also be referred to as a quinoline-basedcrosslinking initiator and should be understood as includinghydrocarbyl-substituted quinolines (as discussed infra) and polymerizedforms thereof. Suitable hydrocarbyl-substituted quinolines include thosewith 1-3 hydrocarbyl groups (e.g., having C₁-C₆) bonded to the carbonsthat are alpha and gamma to the nitrogen of the quinoline; in certainembodiments, the hydrocarbyl-substituted quinoline is polymerized. Incertain embodiments, the hydrocarbyl substitution upon the quinolinecomprises alkyl (linear or branched) of C₁-C₆ (e.g., C₁, C₂, C₃, C₄, C₅,or C₆), preferably C₁-C₂. In other embodiments, the hydrocarbylsubstitution upon the quinoline includes at least one aromatic group(e.g., -phenyl). In yet other embodiments, the hydrocarbyl substitutionis a combination of alkyl and aromatic groups. Particularalkyl-substituted quinolines that may be utilized include, but are notlimited to (1,2-dihydro-2,2,4-trimethylquinoline (TMQ) or a polymerizedform thereof (poly(1,2-dihydro-2,2,4-trimethylquinoline)). In certainembodiments of the first-fourth embodiments, a polymerized quinoline(preferably a polymerized alkyl-substituted quinoline such aspoly(1,2-dihydro-2,2,4-trimethylquinoline)) is used which has amolecular weight of 500-2000 grams/mole (e.g., 500, 600, 700, 800, 900,1000, 1100, 1200, 1300, 1400, or 1500 grams/mole), preferably 1000-1500grams/mole. Without being bound by theory, it is believed that thecrosslink initiator enhances carbon-carbon crosslinking by cleaving thehalogen from the halogenated butyl rubber in one polymer chain, creatinga polymer species capable of bonding by its free radical carbon to aunsaturated carbon in another polymer chain.

-   Additional Ingredients

In certain embodiments of the first-fourth embodiments, the mixture thatcomprises the sealant layer further comprises one or more additionalingredients (i.e., in addition to the at least one rubber, at least onetackifier, one or more extenders, at least one hydroscopic substance,and cure package ingredients as discussed above). In other embodimentsof the first-fourth embodiments, the sealant layer is made from amixture that consists of the at least one rubber, at least onetackifier, one or more extenders, at least one hydroscopic substance,and cure package ingredients (all as discussed above), and contains noother additional ingredients.

Exemplary additional ingredients that may be present in the mixture thatcomprises the sealant layer according to certain embodiments of thefirst-fourth embodiments include, but are not limited to, oils, waxes,antioxidants, and antiozonants. In certain embodiments of thefirst-fourth embodiments wherein the mixture that comprises the sealantlayer includes one or more oils, the total amount of such oil(s) is50-350 phr (e.g., 50 phr, 75 phr, 100 phr, 120 phr, 150 phr, 170 phr,200 phr, 220 phr, 250 phr, 270 phr, 300 phr, 320 phr, 350 phr), or100-300 phr. In other embodiments of the first-fourth embodiments themixture that comprises the sealant layer includes a limited amount ofoil, e.g., less than 100 phr (e.g., less than 90 phr, less than 80 phr,less than 70 phr, less than 60 phr, less than 50 phr, less than 40 phr,less than 30 phr, less than 20 phr, less than 10 phr, less than 5 phr)or even 0 phr. Limiting the amount of oil to one of the foregoingamounts (e.g., less than 100 phr) can be advantageous in limiting oravoiding migration of oil from the sealant layer into the othercomponents of the tire.

-   Detackifier

In certain embodiments of the first-fourth embodiments, the sealantlayer further comprises a detackifier coating on its upper surface (theradially inward facing surface when the sealant layer is adhered to aninner liner of a tire). A detackifier coating upon the upper surface ofthe sealant layer (the radially inward facing surface when the sealantlayer is adhered to an inner liner of a tire) can be especiallybeneficial to avoiding sticking of non-desirable objects such as dirt orinsects by reducing its tackiness or stickiness. According to thefirst-fourth embodiments, a detackifier coating upon the upper surfaceof the sealant layer (i.e., the radially inward facing surface when thesealant layer is adhered to an inner line of a tire) may be especiallyuseful in those embodiments wherein the sealant layer is adhered to theradially inward facing surface of the inner liner since in certain suchembodiments, the upper surface of the sealant layer may be (in certainembodiments) the radially innermost component/surface within the tire.In certain embodiments of the first-fourth embodiments wherein thesealant layer is adhered to the radially outward facing surface of theinner liner, the sealant layer has no detackifier coating upon its uppersurface. In certain embodiments of the first-fourth embodiments, thedetackifier coating can be described as a coating resulting from dryingof a polymer-containing solution (e.g., polymer+water); in certain suchembodiments, the polymer of the detackifier coating comprises a vinylpolymer (e.g., poly(vinyl pyrrolidinone) or PVP, poly(vinyl alcohol) orPVA), ethyl(vinyl alcohol) or EVA, polytetrafluoroethylene or PTFE, or acombination thereof), a polymer formed by reaction of poly(carboxylicacids) with polyols (e.g., polyethylene terephthalate or PET,polycaprolactone, poly(lactic acid) or PLA, poly(lactic-co-glycolicacid) or PLGA, or a combination thereof), a polyether (e.g.,polyethylene glycol or PEG, or polypropylene glycol or PPG, or acombination thereof), a polyurea, a polyurethane, a polyamide elastomer,a polymer latex (containing e.g., water-based polyurethane), or acombination thereof. In other embodiments of the first-fourthembodiments, the detackifier coating is a thermoplastic film such as canbe applied as a dry film to the upper surface of the sealant layer; incertain such embodiments the thermoplastic film comprises at least onepolymer selected from: polyolefins (e.g., low density polyethylene orLDPE); a vinyl chloride polymers (e.g., polyvinyl chloride or PVC,polyvinylidene chloride or PVDC, or a combination thereof); apolyesters; polyamides; polycarbonates; polyurethanes; epoxies;polyacetals; or a combination thereof.

-   Removable Backing/Liner

In certain embodiments of the first embodiment, the sealant layerfurther comprises a removable backing upon its lower surface. Theremovable backing is removed prior to adhering the sealant layer to theradially inward facing surface of the inner liner or prior to adheringthe sealant layer to the radially outward facing surface of the innerliner. By stating that the backing is removable it is intended to conveythat the backing can be removed from the sealant layer by anon-destructive means such as by peeling away of the removable backing.The removable backing can beneficially cover the tacky lower surface ofthe sealant layer allowing for improved storage, shipping and handling.In certain embodiments of the first embodiment wherein the sealant layerincludes a removable backing upon its lower surface, the sealant layeris rolled for storage and shipping; in such embodiments, the sealantlayer is unrolled and the removable backing is removed prior to adheringthe sealant layer to a tire inner liner.

In certain embodiments of the first embodiment, the removable backingcomprises paper, plastic or metal foil coated with a non-stick coatingupon the side contacting the sealant layer; exemplary non-stick coatingsinclude gelatin, silicone, wax, and polymers such as PTFE or PET(partially biaxially oriented polyethylene terephthalate). In certainembodiments of the first embodiment, the removable backing is used inmanufacturing of the sealant layer and allows for extrusion of themixture of ingredients directly onto the removable backing.

-   Barrier Layer

In certain embodiments of the first-fourth embodiments, the sealantlayer further comprises a barrier layer upon its lower surface (itsradially outward facing surface). Such a barrier layer will generallycomprise a relatively thin layer of metal or polymeric film separatingthe tackifier-containing sealant layer from the inner liner and othercomponents of the tire and can be advantageous in limiting or avoidingunwanted migration of ingredients such as tackifier or plasticizer intothe inner liner or into other tire components. In certain embodiments ofthe first-fourth embodiments wherein the sealant layer further comprisesa barrier layer upon its lower surface (its radially inward facingsurface), the barrier layer has a thickness of 0.01 to 0.3 mm,preferably 0.05 to 0.2 mm. In certain embodiments of the first-fourthembodiments wherein the sealant layer further comprises a barrier layerupon its lower surface (its radially outward facing surface), thebarrier layer includes adhesive upon at least its surface which facesthe sealant layer.

-   Curing of the Sealant Layer

In certain embodiments of the first-fourth embodiments, the sealantlayer is cured. By cured is meant that the mixture of ingredientscomprising the sealant layer has been subjected to heating or othertreatment to cross-link the polymer chains, thereby toughening orotherwise improving the properties of the mixture. Preferably, when thesealant layer is cured, such curing takes place prior to adhering thesealant layer to the inner liner of a tire. However, in otherembodiments, the sealant layer may be cured along with the othercomponents of the tire (e.g., in a tire mold). In certain embodiments ofthe first-fourth embodiments, the entire sealant layer is cured. Inother embodiments of the first-fourth embodiments, less than the entiresealant layer is cured (e.g., the upper surface or radially inwardfacing surface of the sealant layer is cured and the remainder isuncured). By remainder is meant the lower surface or radially outwardfacing surface of the sealant layer as well as the portion between theupper and lower surface. In those embodiments of the first-fourthembodiments wherein less than the entire sealant layer is cured, suchcuring can be achieved by various methods such as exposing only onesurface of the sealant layer to heat or other curing treatment or byproducing the sealant layer from two or more sub-layers with at leastone of the sub-layers being cured and at least one other sub-layer beinguncured.

When heat is used to effect curing of the sealant layer, the time andtemperature used may vary. In certain embodiments of the first-fourthembodiments, the sealant layer is cured by heating to a temperature ofabout 40 to about 90° C. (e.g., 40, 45, 50, 55, 60, 65, 70, 75, 80, 85,90° C.), preferably about 50 to about 70° C.; in certain suchembodiments, the heating takes place for a period of about 6 to about 24hours (e.g., 6, 8, 10, 12, 14, 16, 18, 20, 22, 24 hours). In otherembodiments of the first-fourth embodiments, the sealant layer is curedby heating to a relatively higher temperature for a relatively shorterperiod of time such as to a temperature of about 100 to about 150 ° C.(e.g., 100, 110, 120, 130, 140, 150 ° C.); in certain such embodimentsthe heating takes places for a period of about 20 minutes to about 2hours (e.g., 20 minutes, 30 minutes, 40 minutes, 50 minutes, 1 hour,1.25 hours, 1.5 hours, 1.75 hours, 2 hour) or about 30 minutes to about1 hour.

-   Properties of the Sealant Layer and/or Mixture Thereof

In certain embodiments of the first-fourth embodiments, at least one ofthe following is met: (a) the mixture of the sealant layer has anelongation at break of 400 to 1200% (e.g., 500%, 600%, 700%, 800%, 900%,1000%, 1100%, 1200), preferably 600-1000% (e.g., 600%, 650%, 700%, 750%,800%, 850%, 900%, 950%, 1000%, 1050%, 1100%); (b) the mixture of thesealant layer has a tensile strength at break of 0.01 to 5 MPa (e.g.,0.01, 0.05, 0.1, 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5 MPa), preferably0.1-2 MPa (e.g, 0.1, 0.5, 1, 1.5, 2 MPa); or (c) the sealant layer isadhered to the radially inward facing surface of the inner liner or tothe radially outward facing surface of the inner liner with a peelstrength of 2 to 20 N/cm (e.g., 2, 5, 7, 10, 12, 15, 17, or 20 N/cm) or4 to 16 N/cm (e.g., 4, 5, 7, 10, 12, 15, or 16 N/cm), at 23° C.Measurements of elongation at break and tensile strength can be madeupon samples of a mixture containing the same ingredients (e.g., atleast one rubber, at least one tackifier, optionally one or moreextenders, optionally at least one hydroscopic substance, and a curepackage) and made according to the same general procedure (e.g., mixing,curing, etc.) as the rubber-containing mixture portion of the sealantlayer in question. Generally, ASTM-D412 (1998) Method B, can be used todetermine elongation at break and tensile strength at 25° C. Morespecifically, following ASTM D-412, dumbbell-shaped samples with across-section dimension of 4 mm in width and 1.9 mm in thickness at thecenter, cured for 15 minutes at 170° C. can be utilized. Peel strengthcan be determined as described in more detail below.

-   Adhering Sealant Layer To Inner Liner

As discussed above, according to the process of the first embodiment,the sealant layer is adhered either to the radially inward facingsurface of the inner liner so that the lower surface of the sealantlayer faces radially outward to produce a tire containing sealant (i.e.,the sealant layer) or to the radially outward facing surface of the tireinner liner so that the lower surface of the sealant layer facesradially outward when the sealant layer-inner liner combination ispresent in a tire. As also discussed above, according to the secondembodiment, the tire contains a sealant layer wherein the sealant layeris adhered either to the radially inward facing surface of the innerliner so that the lower surface of the sealant layer faces radiallyoutward or to the radially outward facing surface of the inner liner sothat the lower surface of the sealant layer faces radially outward. Incertain embodiments of the first-fourth embodiments, the lower surfaceof the sealant layer is directly adhered to either the radially inwardfacing surface or the radially outward facing surface of the innerliner. In other embodiments of the first-fourth embodiments (e.g., whenthe lower surface of the sealant layer further comprises a barrier layeror an adhesive) the sealant layer may still be described as beingadhered to the inner liner even though it is the barrier layer upon thelower surface of the sealant layer (which, as discussed herein, can beconsidered to be a part of the sealant layer) or the adhesive upon thelower surface of the sealant layer which directly contacts the innerliner.

By stating that the sealant layer is adhered to the radially inwardfacing surface of the inner liner or to the radially outward facingsurface of the inner liner is meant that the sealant layer is securelyattached to the inner liner so as to avoid movement of the sealant layerrelative to the inner liner. It is also advantageous for the sealantlayer to be adhered sufficiently to avoid displacement of the sealantlayer during operation of the tire. In certain embodiments of thefirst-fourth embodiments, the sealant layer is adhered to the radiallyinward facing surface of the inner liner or to the radially outwardfacing surface of the inner liner with sufficient adhesion to exhibit apeel strength of about 2 to about 20 N/cm (e.g., 2, 5, 7, 10, 12, 15,17, or 20 N/cm) or 2 to 20 N/cm, at 23° C.; in certain such embodiments,the peel strength is about or 4 to 16 N/cm (e.g., 4, 5, 7, 10, 12, 15,or 16 N/cm) or 4-16 N/cm, at 23° C. Peel strength measurements can bemade according to ASTM Procedure D903 and/or according to ASTM ProcedureD1876 and utilizing a sample containing a sealant layer adhered to aninner liner surface. The sample may be cut from an assembled sealantlayer-inner liner combination or may be prepared especially for testing(using the same ingredients as the sealant layer-inner liner combinationin question and the same process for assembling same).

In those embodiments of the first-fourth embodiments, where an adhesiveis utilized, the adhesive(s)s used in adhering the sealant layer to theinner layer and/or to the remainder of the tire may cover the entiresurface(s) of the contacting surfaces or may cover less than the entiresurface(s) of the contacting surfaces. By stating that less than theentire surface(s) of the contacting surfaces are covered withadhesive(s) is meant that the adhesive may be applied in variousnon-continuous patterns such as dots or strips. In certain embodimentsof the first-fourth embodiments, one or more of the lower surface of thesealant layer, the outer surface of the barrier layer, the radiallyinner surface of the inner liner, the radially outer surface of theinner liner, the upper surface of the sealant layer, or a combinationthereof may contain a continuously applied adhesive. In otherembodiments of the first-fourth embodiments, one or more of the lowersurface of the sealant layer, the outer surface of the barrier layer,the radially inner surface of the inner liner, the radially outersurface of the inner liner, the upper surface of the sealant layer, or acombination thereof may contain a non-continuously applied adhesive.

In certain embodiments of the first-fourth embodiments, the sealantlayer is adhered to the inner layer of the tire by one or moreadhesives; in certain such embodiments, the adhesive comprises apressure-sensitive adhesive. In other embodiments of the first-fourthembodiments, the sealant layer is adhered to the inner layer of the tirewithout the need for any separate adhesive. In certain embodiments ofthe first embodiment, adhering of the lower surface of the sealant layerto the radially inward facing surface of the inner liner or to theradially outward facing surface of the inner liner includes applicationof an adhesive to at least one of the lower surface of the sealantlayer, the radially inward facing surface of the inner liner, or theradially outward facing surface of the inner liner. In certainembodiments of the first-fourth embodiments, the sealant layer that isprovided includes an adhesive on its lower surface. In certainembodiments of the first-fourth embodiments, the sealant layer that isprovided includes an adhesive on its upper surface (which can aid inadhering to the inner liner in those embodiments wherein the sealantlayer is adhered to the radially outward facing surface of the innerliner; in certain such embodiments, an adhesive will also be presentbetween the lower surface of the sealant layer and the remaining portionof the tire. In certain embodiments of the first-fourth embodiments, theradially inward facing surface of the inner liner includes an adhesiveon its lower surface. In certain embodiments of the first-fourthembodiments, the radially outward facing surface of the inner linerincludes an adhesive on its lower surface. In certain embodiments of thefirst-fourth embodiments, both the lower surface of the sealant layerand the radially inward facing surface of the inner liner includeadhesive. In certain embodiments of the first-fourth embodiments, boththe lower surface of the sealant layer and the radially outward facingsurface of the inner liner include adhesive. In other embodiments of thefirst-fourth embodiments, the lower surface of the sealant layer issufficiently tacky to adhere to the inner liner such that no separateadhesive is required. In certain embodiments of the first-fourthembodiments, wherein an adhesive is used to adhere the lower surface(which becomes radially outward facing) of the sealant layer to theradially inward facing surface of the inner liner or the upper surfaceof the sealant layer (which becomes radially inward facing) to theradially outward facing surface of the inner liner, the adhesivecomprises at least one of the following: (1) rubber (e.g., naturalrubber, butyl rubber, halobutyl rubber, polybutadiene rubber,styrene-butadiene rubber, or a combination thereof), (2) acrylic polymer(e.g., an acrylate made by copolymerizing one or more acrylic ester withone or more other monomers or one of those discussed above), (3)silicone rubber, (4) polyether adhesive, (5) polyurethane polymer; incertain such embodiments, the separate adhesive is a PSA. In certainembodiments of the first-fourth embodiments, the adhesive used to adherethe sealant layer to the inner liner is a water-based adhesive.According to the first-fourth embodiments, in certain embodiments one ormore of the foregoing adhesives may be utilized in adhering the lowersurface of the sealant layer to the remainder of the tire (e.g., bodyply).

In certain embodiments of the first embodiment, adhering of the sealantlayer to the inner liner is achieved by extruding the sealant layerdirectly onto the radially inward facing surface of the inner liner ordirectly upon the radially outward facing surface of the inner liner.Generally, according to such embodiments, the mixture comprising thesealant layer will be at an elevated temperature (e.g., greater thanabout 90° C.) during such extrusion.

In certain embodiments of the first-fourth embodiments, the tire innerliner to which the sealant layer is adhered comprises (includes) apolysiloxane-containing release upon its radially inward facing surface.(Generally, in those embodiments of the first-fourth embodiments whereinthe sealant layer is adhered to the radially outward facing surface ofthe tire inner liner no polysiloxane-containing release will be presentupon the radially outward facing surface of the inner liner.) Such apolysiloxane-containing release may represent the residue from a releasetreatment applied to the inner liner surface prior to curing anddesigned to avoid sticking or co-curing of the inner liner to a bladderduring curing. In certain of those embodiments of the first-fourthembodiments wherein the radially inward facing surface of the tire innerliner includes a polysiloxane-containing release, treatment of theradially inward facing surface of the inner liner to create an adhesionsurface thereon may be necessary in order to adhere the sealant layer;in certain such embodiments, the treatment of the radially inward facingsurface of the inner liner includes application of a rubber-containingliquid comprising at least one conjugated diene monomer-containingrubber, polyurethane, and at least one solvent and in other embodiments,the treatment of the radially inward facing surface of the inner linerincludes application of a rubber-containing liquid comprising at leastone conjugated diene monomer-containing rubber and at least one solvent.In certain embodiments of the first-fourth embodiments, therubber-containing liquid meets at least one of the following: (a) the atleast one conjugated monomer-containing rubber is present in 100 partsand is selected from butyl rubber, halogenated butyl rubber,polybutadiene, natural rubber, polyisoprene, chlorinated polyisoprene,and combinations thereof; (b) the at least one conjugatedmonomer-containing rubber is present in 100 parts and is selected frombutyl rubber, halogenated butyl rubber, or a combination thereof; (c)the polyurethane is present in an amount of 10-50 phr (based upon 100parts of the at least one conjugated monomer-containing rubber); (d) thesolvent comprises a majority by weight of at least one hydrocarbonsolvent; or (e) the solvent comprises a majority by weight of at leastone halogenated aromatic hydrocarbon solvent, at least one halogenatedC1-C6 alkane, at least one halogenated C2-C6 alkene, or a combinationthereof. In other embodiments of the first-fourth embodiments, therubber-containing liquid meets at least one of the following: (a) therubber-containing liquid comprises about 10 to about 45% by weight(e.g., 10, 15, 20, 25, 30, 35, 40, 45%) of conjugated diene monomercontaining rubber (based upon the total weight of the rubber-containingliquid); (b) the rubber of the rubber-containing liquid comprises atleast one of butyl rubber, halogenated butyl rubber, natural rubber,polyisoprene, polybutadiene rubber, styrene-butadiene rubber,styrene-butadiene-isoprene rubber, isoprene-butadiene rubber,polychloroprene rubber, EPDM, or nitrile rubber; (c) at least 80% byweight of the rubber in the rubber-containing liquid comprises acombination of butyl rubber, halogenated butyl rubber, and EPDM rubber;or (d) a majority by weight of the solvent present in therubber-containing liquid comprises water; comprises at least onehydrocarbon solvent; or comprises one or more halogenated solvents.Further details concerning the composition of the rubber-containingliquid can be found in application Ser. No. 62/357009 (filed Jun. 30,2016) or application Ser. No. 62/355568 (filed Jun. 28, 2016) which arehereby incorporated by reference in their entirety. According to certainembodiments of the first-fourth embodiments, once treated to form anadhesion surface, the treated polysiloxane-containing radially inwardfacing surface of the inner liner is adhered to the sealant layer (e.g.,by using an adhesive or in other embodiments without the need for anyseparate adhesive due to the tackiness of the sealant layer).

In yet other embodiments of the first-fourth embodiments, the treatmentof the radially inward facing surface of the inner liner includesapplication of a coating composition comprising: (a) a silyl-terminatedpolymer, (b) optionally at least one plasticizer, (c) at least onetackifier (d) at least one adhesion promoter, (e) optionally at leastone moisture scavenger, (f) at least one catalyst, and (g) optionally atleast one antioxidant to produce a polymer-containing coating upon theradially inward facing surface of the inner liner, thereby creating apolymer-containing coating upon the treated surface of the cured innerliner. Such a coating composition may be useful in embodiments of thefirst-fourth embodiments wherein the radially inward facing surface ofthe inner liner (includes) a polysiloxane-containing release as well asin those embodiments wherein the radially inward facing surface of theinner liner is substantially free of polysiloxane-containing release. Incertain embodiments of the first-fourth embodiments, the coatingcomposition meets at least one of the following: (a) thesilyl-terminated polymer is present in an amount of about 25 to about75% (e.g., 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%,65%, 70%, or 75%) by weight (based upon the total weight of thecomposition used to treat the lower surface of the inner liner) andcomprises a silyl-terminated polyether, a silyl-terminated polyurethane,a silyl-terminated polycarbonate, a silyl-terminated polyisobutylene, ora combination thereof; (b) the plasticizer is present in an amount ofabout 5 to about 40% (e.g., 5%, 10%, 15%, 20%, 25%, 30%, 35%, or 40%) byweight (based upon the total weight of the composition used to treat thelower surface of the inner liner) and comprises a phthalate, adibenzoate, a fatty acid alkyl ester, epoxidized plant oil, or acombination thereof; (c) the tackifier is present in an amount of about5 to about 25% (e.g., 5%, 7%, 10%, 12%, 15%, 17%, 20%, 22%, or 25% byweight) by weight (based upon the total weight of the composition usedto treat the lower surface of the inner liner) and comprises ahydrocarbon resin, a low molecular weight polymer or oligomer, or acombination thereof; (d) the at least one adhesion promoter is presentin an amount of about 1 to about 10% (e.g., 1%, 2%, 3%, 4%, 5%, 6%, 7%,8%, 9%, or 10%) by weight (based upon the total weight of thecomposition used to treat the lower surface of the inner liner) andcomprises a bi-functional silane; (e) the at least one moisturescavenger is present in an amount of about 0.5 to about 5% (e.g., 0.5%,1%, 1.5%, 2%, 2.5%, 3%, 3.5%, 4%, 4.5%, or 5%) by weight (based upon thetotal weight of the composition used to treat the lower surface of theinner liner) and comprises a vinyl alkoxysilane, analkyltrialkoxysilane, an oxazolidine, calcium oxide, anhydrous silica,anhydrous sodium sulfate, anhydrous calcium sulfate, a zeolites, or acombination thereof; (f) the at least one catalyst is present in anamount of about 0.1 to about 5% (e.g., 0.1%, 0.5%, 1%, 1.5%, 2%, 2.5%,3%, 3.5%, 4%, 4.5%, or 5%) by weight (based upon the total weight of thecomposition used to treat the lower surface of the inner liner) andcomprises at least one basic compound selected from alkali metalhydroxides, silanolates, organic amines, alkali metal carbonates, alkalimetal bicarbonates, and combinations thereof or from at least one acidiccompound selected from sulfuric acid, phosphoric acid, hydrochloricacid, organic acids, Lewis acids, metal halides, organotin compounds,titanium compounds, and combinations thereof; or (g) the at least oneantioxidant (when present) is present in an amount of about 0.1 to about3% (e.g., 0.1%, 0.5%, 1%, 1.5%, 2%, 2.5%, or 3%) by weight (based uponthe total weight of the composition used to treat the lower surface ofthe inner liner) and comprises a hindered phenol, a hindered amine, acatechol, a phosphate ester, or a combination thereof. Further detailsconcerning the composition of the coating composition can be found inapplication Ser. No. 62/434,591 (filed Dec. 15, 2016) which is herebyincorporated by reference in their entirety.

In certain embodiments of the first-fourth embodiments, the tire innerliner to which the sealant layer is adhered is substantially free ofpolysiloxane-containing release upon its radially inward facing surface.By substantially free of polysiloxane moieties is meant that theradially inward facing surface of the inner liner comprises less than 1%by weight, less than 0.5% by weight, less than 0.1% by weight, or even0% by weight polysiloxane moieties. In those embodiments of thefirst-fourth embodiments wherein the radially inward facing surface ofthe inner liner is substantially free of polysiloxane-containingrelease, the sealant layer may be adhered to the inner liner without theneed for any treatment of the radially inward facing surface of theinner liner; in certain such embodiments, the sealant layer is adheredto the radially inward facing surface of the inner liner using anadhesive. In certain embodiments of the first-fourth embodiments whereinthe tire inner liner is substantially free of polysiloxane-containingrelease upon its radially inward facing surface, a rubber containingliquid is used to treat the radially inward facing surface of the innerliner prior to adhering the sealant layer, creating an adhesive layerupon the surface of the inner liner; preferably, such a rubbercontaining liquid meets at least one of the following: (a) the at leastone conjugated monomer-containing rubber is present in 100 parts and isselected from butyl rubber, halogenated butyl rubber, polybutadiene,natural rubber, polyisoprene, chlorinated polyisoprene, and combinationsthereof; (b) the at least one conjugated monomer-containing rubber ispresent in 100 parts and is selected from butyl rubber, halogenatedbutyl rubber, or a combination thereof; (c) the polyurethane is presentin an amount of 10-50 phr (based upon 100 parts of the at least oneconjugated monomer-containing rubber); (d) the solvent comprises amajority by weight of at least one hydrocarbon solvent; or (e) thesolvent comprises a majority by weight of at least one halogenatedaromatic hydrocarbon solvent, at least one halogenated C1-C6 alkane, atleast one halogenated C2-C6 alkene, or a combination thereof.

In certain embodiments of the fourth embodiment, the tire that isprovided comprises a punctured tire in need of repair. In such anembodiment, it is contemplated that the sealant layer could be added toa punctured tire during the process of repairing the tire, therebyresulting in a tire containing sealant (i.e., the sealant layer) eventhough the tire when punctured lacked any sealant. In certainembodiments of the second-fourth embodiments, it is contemplated thatthe sealant layer is adhered to the inner liner by the tire manufactureras part of the manufacturing process such that a tire containing sealant(i.e., the sealant layer) is installed upon a vehicle as part of thevehicle's original equipment or utilized as a replacement tire upon avehicle. In yet other embodiments of the second-fourth embodiments, itis contemplated that the sealant layer is adhered to the inner liner ofa new replacement tire by an entity other than the tire manufacturer(e.g., by the tire installer) prior to installation of the replacementtire onto a vehicle.

-   Inner Liner

As discussed above, according to the first-fourth embodiments, thesealant layer is adhered to the inner liner of the tire. Morespecifically, the sealant layer is adhered either to the radially inwardfacing surface of the inner liner so that the lower surface of thesealant layer faces radially outward or to the radially outward facingsurface of the inner liner so that the lower surface of the sealantlayer faces radially outward. As used herein, the term inner linershould be understood to encompass both traditional-type inner liners(e.g., comprising a layer of butyl or halogenated butyl rubber),spray-on inner liners (e.g., comprising a composition which is sprayedor coated onto the radially inner surface of the tire to produce gasbarrier properties without any separate butyl rubber-containing layer),and combinations thereof (e.g., a butyl rubber-containing layer with anair barrier sprayed upon). Additionally, as discussed further herein, itshould be understood that in certain embodiments of the first-fourthembodiments, the tire inner liner to which the sealant layer is adheredmay (at the point in time of the adhering of the sealant layer to theinner liner) be a component in a tire which also contains one or morebelts and a tread; generally, in such embodiments, the tire will havealready been cured when the sealant layer is adhered to the radiallyinward facing surface of the inner liner. In other embodiments of thefirst-fourth embodiments, the tire inner liner to which the sealantlayer is adhered may not yet (at the point in time of adhering of thesealant layer to the inner liner) be a component in a tire which alreadyincludes one or more belts and a tread; generally, in such embodiments,the tire will be in the process of being built (e.g., the one or morebelts and the tread will be added after the sealant layer is adhered tothe inner liner) and the tire will be cured after the sealant layer isadhered to the inner liner. Embodiments wherein the tire inner liner towhich the sealant layer is adhered are not yet a component in a tirewhich already includes one or more belts and a tread may be referred to(e.g., when incorporated into a tire) as containing a built-in sealantlayer.

-   Tire

As discussed above, according certain embodiments of the process of thefirst embodiment, the sealant layer is adhered to the radially inwardfacing surface of the inner liner to produce a sealant layer-tire innerliner combination and in other embodiments the sealant layer is adheredto the radially outward facing surface of the inner liner to produce asealant layer-tire inner liner combination. Generally, according to thefirst embodiment, the tire inner liner that is provided may be invarious stages of manufacture but will generally include a radiallyinward facing surface. (The inner liner can also be described asincluding a radially outward facing surface.) A tire that incorporates asealant layer-inner liner combination produced according to the firstembodiment will include in its finished version (in addition to theinner liner and the sealant layer) one or more belts and a tread, and,thus, as part of the overall process of the first embodiment, one ormore belts and a tread will generally be provided. In certainembodiments of the first embodiment, the sealant layer is adhered to theradially inward facing surface of a tire inner liner that has alreadybeen assembled with one or more belts and a tread; such a tire innerliner has preferably been cured prior to having the sealant layeradhered to the radially inward facing surface of its inner liner. Inother embodiments of the first embodiment, the sealant layer is adheredto the radially outward facing surface of a tire inner liner prior tothe inner liner being assembled with one or more belts or a tread; insuch embodiments, the addition of the one or more belts, and the treadas well as the overall curing of the tire takes place after the sealantlayer-tire inner liner combination is produced. Similarly, in certainembodiments of the second-fourth embodiments, the sealant layer isadhered to the outward facing surface of the tire inner liner and othercomponents of the tire including the one or more belts and the tread areradially outward of the sealant layer; in certain such embodiments, thelower surface of the sealant layer is adhered to a body ply of the tire.

-   Process of Recovering Used Tire Components

According to the third embodiment, a process is provided for recoveringone or more components of a used tire. The recovery may be for purposesof recycling the materials of one or more components of the used tire. Atire containing a sealant layer according to the second embodiment maybe particularly suitable for recovering one or more components of theused tire in that the sealant layer may be removed from the tire byseparating of the sealant layer from the inner liner. In certainembodiments of the third embodiment, the inner liner of the used tirehas a radially inward facing surface which comprises (includes) apolysiloxane-containing release which prior to adhering of the sealantlayer had been treated (e.g., with a rubber-containing liquid comprisingat least one conjugated diene monomer-containing rubber, polyurethaneand at least one solvent) to create an adhesion surface thereon. Aninner liner which includes such a treated polysiloxane-containingrelease may allow for easier and more complete removal of the adheredsealant layer from the used tire. The presence of sealant or a sealantlayer within a tire may inhibit the ability to recover or recyclecomponents of the tire due to its stickiness which can lead to cloggingof recycling equipment (e.g., shredder).

-   Process for Repairing A Punctured Tire

According to the fourth embodiment disclosed herein, a process forrepairing a punctured tire is provided. The process comprises: providinga tire containing a sealant layer according to the second embodiment,wherein the tire contains at least one puncture of its inner liner;identifying the at least one puncture; repairing the puncture either by(a) removing the portion of the sealant layer surrounding the puncture,thereby creating a gap in the sealant layer; and adhering a new portionof sealant to the gap, or (b) adding a new portion of sealant to thepuncture; thereby repairing the punctured tire. In certain embodimentsof the fourth embodiment, the new portion of sealant that is providedcomprises a sealant layer as described herein for the first, second andthird embodiments. In those embodiments of the fourth embodiment whererepairing the puncture comprises (a), the new portion of sealantpreferably comprises a sealant layer as described herein for the first,second and third embodiments. In other embodiments of the fourthembodiment, the new portion of sealant that is provided comprises anysealant material capable of sealing the puncture. In certain suchembodiments, the portion of the sealant layer surrounding the punctureincludes at least 2.5 to 5 cm (e.g., 2.5, 3, 3.5, 4, 4.5, 5 cm)surrounding the puncture (or punctures); in such embodiments the portionremoved may be square, rectangular, triangular, circular or oval inshape. In certain embodiments, the portion of the sealant layer that isremoved may include the entire thickness of that portion (e.g., from theradially innermost surface of the sealant layer portion through theopposing surface of the sealant layer portion (lower surface) whichfaces radially outward and is adhered to the inner liner. In otherembodiments, the portion of the sealant layer that is removed mayinclude less than the entire thickness of that portion (e.g., from theradially innermost surface of the sealant layer portion but not throughthe opposing surface of the sealant layer portion. The portion ofsealant layer that is used to repair the gap can be understood as havingthe structure and composition of the sealant layer described herein foruse in the process of the first embodiment.

In certain embodiments of the fourth embodiment, the process is modifiedso that more than just the portion of the sealant layer surrounding thepuncture is removed. In such embodiments, either the entire sealantlayer is removed and a new sealant layer is added or a portion of thesealant layer including the puncture but also comprising the entirewidth of the sealant layer (e.g., belt-edge-to-belt-edge) and having aradial length at least 2.5 to 5 cm (e.g., 2.5, 3, 3.5, 4, 4.5, 5 cm)beyond each side of the puncture is removed; in certain suchembodiments, the portion of the sealant layer removed may be square,rectangular or trapezoidal in shape.

In certain embodiments of the fourth embodiment, the removal of at leasta portion of the sealant layer corresponding to the puncture isfacilitated by use of a heated blade or other heated tool. In otherembodiments of the fourth embodiment, the removal of at least a portionof the sealant layer corresponding to the puncture is facilitated by theuse of laser-guided cutting. In such embodiments, during removal of theat least a portion of the sealant layer corresponding to the puncture,care must be taken to avoid puncture or tearing of the inner liner andit may be preferable to remove less than the entire thickness of theportion that is removed.

In certain embodiments of the fourth embodiment, identification of theat least one puncture may be facilitated if the sealant layer of thetire is non-black in color (e.g., white or a non-white color such asred, blue, orange, yellow, green, purple, or pink).

To the extent that the term “includes” or “including” is used in thespecification or the claims, it is intended to be inclusive in a mannersimilar to the term “comprising” as that term is interpreted whenemployed as a transitional word in a claim. Furthermore, to the extentthat the term “or” is employed (e.g., A or B) it is intended to mean “Aor B or both.” When the applicants intend to indicate “only A or B butnot both” then the term “only A or B but not both” will be employed.Thus, use of the term “or” herein is the inclusive, and not theexclusive use. See Bryan A. Garner, A Dictionary of Modern Legal Usage624 (2d. Ed. 1995). Also, to the extent that the terms “in” or “into”are used in the specification or the claims, it is intended toadditionally mean “on” or “onto.” Furthermore, to the extent the term“connect” is used in the specification or claims, it is intended to meannot only “directly connected to,” but also “indirectly connected to”such as connected through another component or components.

While the present application has been illustrated by the description ofembodiments thereof, and while the embodiments have been described inconsiderable detail, it is not the intention of the applicant torestrict or in any way limit the scope of the appended claims to suchdetail. Additional advantages and modifications will readily appear tothose skilled in the art. Therefore, the application, in its broaderaspects, is not limited to the specific details and embodimentsdescribed. Accordingly, departures may be made from such details withoutdeparting from the spirit or scope of the applicant's general inventiveconcept.

This application discloses several numerical range limitations thatsupport any range within the disclosed numerical ranges even though aprecise range limitation is not stated verbatim in the specificationbecause the embodiments could be practiced throughout the disclosednumerical ranges. With respect to the use of substantially any pluraland/or singular terms herein, those having skill in the art cantranslate from the plural to the singular and/or from the singular tothe plural as is appropriate to the context and/or application. Thevarious singular/plural permutations may be expressly set forth hereinfor sake of clarity. As well, all numerical limitations and ranges thatare preceded by the word “about” should be understood to include theparticular number or range without the about as if fully set forthherein.

What is claimed is: 1-19. (canceled)
 20. A process for producing asealant layer-tire inner liner combination comprising: a. providing atire inner liner, wherein the inner liner includes a radially inwardfacing surface and a radially outward facing surface, b. providing asealant layer having an upper surface, a lower surface, and a thicknessof 2-8 mm, and comprising a mixture of i. 100 parts of at least onerubber selected from the group consisting of butyl rubber (optionallyhalogenated), natural rubber, polyisoprene, polybutadiene rubber,styrene-butadiene rubber, styrene-butadiene-isoprene rubber,isoprene-butadiene rubber, polychloroprene rubber, EPDM, nitrile rubber,polyisobutylene, and combinations thereof; ii. 90-500 phr of at leastone tackifier; iii. optionally one or more extenders in a total amountof no more than 55 phr; iv. optionally at least one hydroscopicsubstance in an amount of 0.5 to 10 phr; and v. a cure package; and c.adhering the sealant layer either: i. to the radially inward facingsurface of the inner liner so that the lower surface of the sealantlayer faces radially outward, or ii. to the radially outward facingsurface of the inner liner so that the lower surface of the sealantlayer faces radially outward, thereby producing a sealant layer-tireinner liner combination.
 21. The process of claim 20, wherein at least60 parts of the 100 parts of rubber comprise butyl rubber, halogenatedbutyl rubber, EPDM, or a combination thereof, and up to 200 parts of theat least one tackifier comprise polybutene.
 22. The process of claim 20,wherein the at least one tackifier comprises at least one of a. at leastone low molecular weight polymer or oligomer having a Mw of 700-150,000grams/mole and a Mn of 500-100,000 grams/mole; b. at least one resinselected from the group consisting of phenolic resins, aliphatic resins,cycloaliphatic resins, aromatic resins, terpene resins, guayule resins,and combinations thereof; or c. polybutene having a Mn of 500-5000grams/mole.
 23. The process of claim 20, wherein the at least onetackifier comprises a polar-functionalized polybutadiene having a Mn of1200 to 10000 grams/mole, preferably maleic anhydride functionalizedpolybutadiene.
 24. The process of claim 20, wherein the mixture of thesealant layer includes 10-45 phr of extender comprising carbon black,clay, titanium dioxide, calcium carbonate, graphite, talc, or acombination thereof.
 25. The process of claim 20, wherein the extenderincludes 1-10 phr of fumed silica.
 26. The process of claim 20, whereinthe cure package includes a quinoline-based crosslinking initiator. 27.The process of claim 20, wherein the sealant layer is cured.
 28. Theprocess of claim 20, wherein the upper surface of the sealant layer iscured and the remainder is uncured.
 29. The process of claim 20, whereinthe upper surface of the sealant layer further comprises an outwardlyfacing detackifier coating.
 30. The process of claim 20, wherein thesealant layer further comprises a removable backing upon its lowersurface which is removed prior to (c).
 31. The process of claim 20,wherein the radially inward facing surface of the inner liner comprisesa polysiloxane-containing release and the adhering of the lower surfaceof the sealant layer in (c) is preceded by treating the radially inwardfacing surface of the inner liner with a rubber-containing liquidwherein the rubber-containing liquid comprises at least one conjugateddiene monomer-containing rubber, polyurethane and at least one solventto create an adhesion surface thereon.
 32. The process of claim 20,wherein the radially inward facing surface of the inner liner issubstantially free of polysiloxane-containing release and the adheringof the lower surface of the sealant layer in (c) includes use of anadhesive.
 33. The process of claim 20, wherein the lower surface of thesealant layer further comprises a barrier layer.
 34. The process ofclaim 20, wherein the sealant layer has a width that varies by no morethan 5% from the width of the radially inward facing surface of theinner liner of the tire as measured from belt-edge-to-belt edge.
 35. Atire containing the sealant layer-tire inner liner combination producedaccording to the process of claim
 20. 36. A tire containing a sealantlayer comprising one or more belts, a road-contacting tread, an innerliner with a radially inward facing surface and a radially outwardfacing surface, and a sealant layer having an upper surface, a lowersurface, and a thickness of 2-8 mm, wherein the sealant layer is adheredto either to the radially inward facing surface of the inner liner sothat the lower surface of the sealant layer faces radially outward or tothe radially outward facing surface of the inner liner so that the lowersurface of the sealant layer faces radially outward, wherein the sealantlayer comprises a mixture of i. 100 parts of at least one rubberselected from the group consisting of butyl rubber (optionallyhalogenated), natural rubber, polyisoprene, polybutadiene rubber,styrene-butadiene rubber, styrene-butadiene-isoprene rubber,isoprene-butadiene rubber, polychloroprene rubber, EPDM, nitrile rubber,polyisobutylene, and combinations thereof; ii. 90-500 phr of at leastone tackifier; iii. optionally one or more extenders in a total amountof no more than 55 phr; iv. optionally at least one hydroscopicsubstance in an amount of 0.5 to 10 phr; and v. a cure package.
 37. Thetire of claim 36, wherein (a) at least 60 parts of the 100 parts ofrubber comprise butyl rubber, halogenated butyl rubber, EPDM, or acombination thereof, and (b) the at least one tackifier comprises atleast one of i. at least one low molecular weight polymer or oligomerhaving a Mw of 700-150,000 grams/mole and a Mn of 500-100,000grams/mole; ii. at least one resin selected from the group consisting ofphenolic resins, aliphatic resins, cycloaliphatic resins, aromaticresins, terpene resins, guayule resins, and combinations thereof; oriii. polybutene having a Mn of 500-5000 grams/mole.
 38. A process ofrecovering one or more components of a used tire, the process comprisingproviding a tire containing a sealant layer according to claim 36, andremoving the sealant layer from the tire by separating the sealant layeraway from the inner liner.
 39. A process for repairing a punctured tire,the process comprising providing a tire containing a sealant layercomprising one or more belts, a road-contacting tread, an inner linerwith a radially inward facing surface and a radially outward facingsurface, and a sealant layer having an upper surface, a lower surface,and a thickness of 2-8 mm, wherein the sealant layer is adhered toeither to the radially inward facing surface of the inner liner so thatthe lower surface of the sealant layer faces radially outward or to theradially outward facing surface of the inner liner so that the lowersurface of the sealant layer faces radially outward, wherein the sealantlayer comprises a mixture of i. 100 parts of at least one rubberselected from the group consisting of butyl rubber (optionallyhalogenated), natural rubber, polyisoprene, polybutadiene rubber,styrene-butadiene rubber, styrene-butadiene-isoprene rubber,isoprene-butadiene rubber, polychloroprene rubber, EPDM, nitrile rubber,polyisobutylene, and combinations thereof; ii. 90-500 phr of at leastone tackifier; iii. optionally one or more extenders in a total amountof no more than 55 phr; iv. optionally at least one hydroscopicsubstance in an amount of 0.5 to 10 phr; and v. a cure package; andwherein the tire contains at least one puncture of the inner liner,identifying the at least one puncture, repairing the at least onepuncture either by a. removing the portion of the sealant layersurrounding the puncture thereby creating a gap in the sealant layer,and adhering a new portion of sealant to the gap, or b. adding a newportion of sealant to the puncture, thereby repairing the puncturedtire.